bomag bw180ad
TRANSCRIPT
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Instructions for repair
Catalogue number
008 912 53 06/2002
BW 180 AD101 870 00 ....
Tandem Vibratory Roller
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Table of Contents
BOMAG 3008 912 53
General 5
1.1 Foreword 6
1.2 Safety regulations 7
1.3 General repair instructions 9
1.4 Tightening torques 11
1.5 Connection overview 12
Tests and adjustments 15
2.1 Technical data 16
2.2 Special tools 19
2.3 Checking the rotation speeds 21
2.4 Pressure tests in the travel circuit 23
2.5 Checking / adjusting the neutral positions of the travel pump 25
2.6 Check the setting of the high pressure relief valves in the travel circuit 28
2.7 Pressure measurements in the vibration circuit 30
2.8 Check the setting of the high pressure relief valves in the vibration circuit 31
2.9 Checking / adjusting the vibrator shaft speeds 33
2.10 Checking the leakage rate of the vibration motor 34
2.11 Pressure test in steering circuit 35
2.12 Operation of display module for ESX-control 37
2.13 Driving against the closed brake 38
2.14 Adjusting the machine type 39
2.15 Calibration of the angle transducers 41
2.16 Adjusting the angle transducers 43
2.17 Automatic detection of step currents for the steering valves 45
2.18 Adjusting the type of travel range switch 47
2.19 Resetting the step currents in the travel system 49
2.20 Automatic detection of step currents in the travel system 50
2.21 Showing stored faults 53
2.22 Deleting stored faults 54
Flushing 55
3.1 Special tool: 56
3.2 Flushing shematic for front drum drive 58
3.3 Flushing schematic for rear drum drive system 60
3.4 Flashing the travel circuit 623.5 Flushing schematic for vibration drive 72
3.6 Flushing the vibration circuit 74
Trouble shooting 81
4.1 General 82
4.2 Trouble shooting diagram 83
Drum 103
5.1 Special tools 104
5.2 Repair overview for drum 106
5.3 Removing and installing the drum 108
5.4 Removing and installing the vibrator unit on the drum drive side 114
5.5 Removing and installing the vibrator unit on the vibration drive side 119
5.6 Repairing the vibrator unit on the drum drive unit 129
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Table of Contents
BOMAG4 008 912 53
5.7 Repairing the vibrator unit on the vibration drive unit 134
5.8 Dismantling, assembling the change-over weights 140
Pivot steering 143
6.1 Removing, repairing and installing the pivot steering 144
6.2 Repairing the oscillation joint 148
Suppliers documentation 153
7.1 A4VG 155
7.2 A10VG 201
7.3 MS/MSE 02 to 18 255
7.4 Vibration motor A2FM 32 305
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1 General
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1.1 Foreword
Introduction
These repair instructions contain all necessary infor-mation for training and repair work.
Notes on maintenance, care and trouble shooting canbe found in the operating and maintenance instruc-
tions. 1 General
2 Tests and adjustments
3 Flushing
4 Trouble shooting
5 Drum
6 Pivot steering
7 Components
This instruction manual contains only assemblygroups needed for this type of machine.
The repair instructions describe the removal or dis-mantling and assembly of components and assemblygroups.
The repair of disassembled assembly groups is de-scribed as far as this makes sense with respect toavailable tools and spare parts supply and as far as itcan be understood by a skilled mechanic.
Danger
Danger of injury
Please observe strictly the safety regulations in
these operating instructions and the applicableaccident prevention regulations.
Spare parts needed for repairs can be taken from thespare parts catalogue for the machine.
You should only use genuine BOMAG spare parts.
These repair instructions are not subject of an updat-ing service; for this reason we would like to draw yourattention to our additional technical service bulletins.
In case of a new release all necessary changes will beincluded.
In the course of technical development we reserve theright for technical modifications without prior notifica-tion.
Information and illustrations in this repair manual mustnot be reproduced and distributed, nor must they beused for the purpose of competition. All rights accord-ing to the copyright law remain expressly reserved.
BOMAG GmbH & Co. OHG
Printed in Germany
Copyright by BOMAG
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1.2 Safety regulations
Important notes
These safety regulations must be read and ap-plied by every person involved in the repair of thismachine. The applicable accident prevention in-structions and the safety regulations in the oper-
ating and maintenance instructions must beadditionally observed.
Repair work shall only performed by appropriatelytrained personnel or by the after sales service ofBOMAG.
These repair instructions contain headers like „Note“,„Attention“, „Danger“ and „Environment“, which mustbe strictly complied with in order to avoid dangers forhealth and for the environment.
Danger
Paragraphs marked like this highlight possibledangers for persons.
Caution
Paragraphs marked like this highlight possibledangers for machines or parts of the machine.
Note
Paragraphs marked like this contain technical infor- mation for the optimal economical use of the machine.
Environment
Paragraphs marked like this point out practicesfor safe and environmental disposal of fuels andlubricants as well as replacement parts.
Observe the regulations for the protection of theenvironment.
General
Before starting repair work stand the machine onlevel and solid ground.
Always secure the machine against unintended roll-ing.
Secure the engine reliably against unintentionalstarting.
Mark a machine that is defective or being repairedby attaching a clearly visible warning tag to thesteering wheel.
On machines with articulated joint keep the articu-lated joint locked during work.
Use protective clothes like hard hat, safety bootsand gloves.
Keep unauthorized persons away from the machineduring repair work.
Tools, lifting gear, lifting tackle, supports and otherauxiliary equipment must be fully functional and insafe condition.
Use only safe and approved lifting gear of sifficientload bearing capacity to remove and install parts orcomponents from and to the machine.
Be careful with cleansing agents. Do not use easilyinflammable or harmful substances, such as gaso-line or paint thinners for cleaning.
Cleaning or repair work on the fuel tank is very dan-gerous. Do not smoke or allow any ignitable sparksor open fire in the vicinity when cleaning or repairinga tank. .
When performing welding work strictly comply withthe respective welding instructions.
Special safety regulations
Use only genuine BOMAG spare parts for repairpurposes. Original parts and accessories havebeen specially designed for this machine.
We wish to make explicitly clear that we have nottested or approved any parts or accessories notsupplied by us. The installation and/or use of suchproducts may therefore have an adverse effect onthe specific characteristics of the machine andthereby impair the active and/or passive drivingsafety. The manufacturer explicitly excludes any li-ability for damage caused by the use of non-original
parts or accessories. Unauthorized changes to the machine are prohibit-
ed for safety reasons.
If tests on the articulated joint need to be performedwith the engine running, do not stand in the articu-lation area of the machine, danger of injury!
Do not perform cleaning work while the engine isrunning.
If tests must be performed with the engine runningdo not touch rotating parts of the engine, danger ofinjury.
Exhaust gases are highly dangerous. Always en-sure an adequate supply of fresh air when startingthe engine in closed rooms.
Refuel only with the engine shut down. Ensure strictcleanliness and do not spill any fuel.
Keep used filters in a separate waste container anddispose of environmentally.
Dispose of oils and fuel environmentally when per-forming repair or maintenance work.
Do not refuel in closed rooms.
Do not heat up oil higher than 160 °C because itmay ignite.
Wipe off spilled oil and fuel.
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Do not smoke when refuelling or when checking theacid level in the battery.
Do not check the acid level of the battery with a na-ked flame, danger of explosion!
Old batteries contain lead and must be properly dis-
posed of. There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature.
on machines with rubber tires a tire may busr if in-correctly assembled. This can cause severe injury.
Do not exceed the specified highest permissible tirepressure.
Hydraulics
Hydraulic oil escaping under pressure can pene-trate the skin and cause severe injury. You should
therefore relieve the pressure in the system beforedisconnecting any lines.
Before applying pressure to the system make surethat all line connections and ports have been prop-erly tightened and are in perfect condition.
Hydraulic oil leaking out of a small opening canhardly be noticed, therefore please use a piece ofcardboard or wood when checking for leaks. Whenbeing injured by hydraulic oil consult a physician im-mediately, as otherwise this may cause severe in-fections.
Do not step in front of or behind the drums/wheelswhen performing adjustment work in the hydraulicsystem while the engine is running. Block drumsand/or wheels with wedges.
Reattach all guards and safety installations afterall work has been completed.
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1.3 General repair instructions
General
Before removing or disassembling and parts, hosesor components mark these parts for easier assem-bly.
Before assembly oil or grease all parts, as far as this
is necessary.
Hydraulic system
Caution
Do not open any hydraulic components if youhave not been properly trained and without exactknowledge.
Please note
Cleanliness is of utmost importance. Make sure that
no dirt or other contaminating substances can enterinto the system.
Clean fittings, filler covers and the area around suchparts before disassembly to avoid entering of dirt.
Before disconnecting hoses, pipes or similar relievethe system pressure with the engine shut down.
During repair work keep all openings closed withclean plastic plugs and caps.
Do not run pumps and motors without oil.
When cleaning hydraulic components take care notto damage any fine machine surfaces.
Chemical and rubber soluble cleansing agents mayonly be used to clean metal parts. Do not use suchsubstances to clean seals and gaskets.
Rinse of cleaned parts thoroughly, dry them withcompressed air and apply anti-corrosion oil immedi-ately. Do not install parts that show traces of corro-sion.
Avoid the formation of rust on fine machined causedby hand sweat.
Grease must not used as a sliding agent for assem-bly work. Use hydraulic oil.
Do not start the engine after the hydraulic oil hasbeen drained off.
Use only the specified pressure gauges. Risk ofdamaging the pressure gauges under too high pres-sure.
Clean ports and fittings before removal so that nodirt can enter into the hydraulic system.
Check the hydraulic oil level before and after thework.
Use only clean oil according to specification.
Check the hydraulic system for leaks, find and rec-tify the cause.
Fill new hydraulic units with hydraulic oil beforestarting operation.
After changing a component thoroughly flush andbleed the entire hydraulic system.
Perform measurements at operating temperature of
the hydraulic oil (approx. 40 °C). After changing a component perform a high and
charge pressure test, if necessary check the speedof the exciter shaft.
The operating pressure of the exciter shaft to agreat extent depends on the base under the vibrat-ing drum. If the soil is too hard place the drums onold rubber tires. Do not activate the vibration on ahard, concreted base, danger of bearing damage.
After the completion of all tests perform a test runand then check all connections and fittings for leakswith the engine still stopped and the hydraulic sys-tem depressurized.
Before commissioning
After changing a component clean the hydraulic oiltank thoroughly.
Fill the housings of hydraulic pumps and motorswith hydraulic oil.
Use only hydraulic oils according to the specifica-tion in the maintenance instructions.
After changing a component clean the hydraulicsystem as described in the flushing instructions inorder to prevent all other components from beingdamaged by abrasion and metal chips remaining inthe system.
Change the hydraulic oil filter.
Commissioning
Bleed the hydraulic circuits.
Start up the system without load.
Check the hydraulic oil level in the tank, fill up oil ifnecessary.
After commissioning Check system pressures and speeds.
Check fittings and flanges for leaks.
After each repair check all adjustment data, rota-tional speeds and nominal values in the hydraulicsystem, adjust if necessary.
Do not adjust pressure relief valves and controlvalves to values above their specified values.
Electrical system
Always disconnect the battery before starting workin the electrical system.
Ensure correct polarity when connecting the bat-tery.
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Do not check voltage by tapping against ground.
When performing welding work always fasten theearth clamp of the welding unit in the immediate vi-cinity of the welding location. Strictly disconnect thecables from the generator before starting work.
Seals and gaskets
Generally use new seals and gaskets when per-forming assembly work. The required seal kits areavailable as spare parts.
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1.4 Tightening torques
Tightening torques
Tighten fastening screws and nuts according to the table of tightening torques.
Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.
Caution
Self-locking nuts must be generally renewed.
The values result in a 90% utilization of the screw’s yield point at a coefficient of friction µ total = 0,14.
Compliance with the tightening torques is checked with torque wrenches.
Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.
The values specified in the table apply for screws black, oiled and with surface protection A4C.
The quality designation of the screws is stamped on the screw heads.
Tightening torques for screws with metric unified thread
Screw dimensionTightening torque Nm* (ft-lb)
8.8 10.9 12.9
M4 3 (2) 5 (4) 5 (4)
M5 6 (4) 9 (7) 10 (7)
M6 10 (7) 15 (11) 18 (13)
M8 25 (18) 35 (26) 45 (33)
M10 50 (37) 75 (55) 83 (61)
M12 88 (65) 123 (91) 147 (108)M14 137 (101) 196 (145) 235 (173)
M16 211 (156) 300 (221) 358 (264)
M18 290 (213) 412 (303) 490 (361)
M20 412 (304) 578 (426) 696 (513)
M22 560 (413) 785 (559) 942 (695)
M24 711 (524) 1000 (738) 1200 (885)
M27 1050 (774) 1480 (1092) 1774 (1308)
M30 1420 (1047) 2010 (1482) 2400 (1770)
Tightening torques for screws with metric fine thread
Screw dimension
Tightening torques Nm* (ft-lb)
* Strength classes for screws with untreated, non-lubricated surface.
8.8 10.9 12.9
M8 x 1 26 (19) 37 (27) 48 (35)
M10 x 1.25 52 (38) 76 (56) 88 (65)
M12 x 1.25 98 (72) 137 (101) 126 (119)
M12 x 1.5 93 (69) 127 (94) 152 (112)
M14 x 1.5 152 (112) 216 (159) 255 (188)
M16 x 1.5 225 (166) 318 (235) 383 (282)
M18 x 1.5 324 (239) 466 (344) 554 (409)
M20 x 1.5 461 (340) 628 (463) 775 (572)
M22 x 1.5 618 (456) 863 (636) 1058 (780)
M24 x 2 780 (575) 1098 (808) 1294 (1416)
M27 x2 1147 (846) 1578 (1164) 1920 (1416)M30 x 2 1568 (1156) 2254 (1662) 2695 (1988)
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Fig. 1
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1 Proportional valve, travel system
2 Pressure test port X4, control chamber pressure,travel pump
3 Pressure test port MB high pressure, reverse trav-
el
4 High pressure port B to rear travel motor, highpressure reverse travel
5 High pressure port B to front travel motor, highpressure reverse travel
6 Adjustment screw, high frequency
7 High pressure port A to rear travel motor, highpressure forward travel
8 High pressure port A to front travel motor, highpressure forward travel
9 Port T1, leak oil tank A
10 High pressure port B, to vibration shut-off valve,
high pressure low frequency11 High pressure port A, to vibration shut-off valve,
high pressure high frequency
12 Magnetic coil Y57, low frequency
13 High pressure test port, low frequency
14 High pressure relief valve, vibration, 420 bar
15 Magnetic coil, high frequency
16 Pressure test port X2, vibration pump
17 Pressure test port X1, vibration pump
18 Pressure test port R, vibration pump case pres-sure
19 Proportional valve, travel system
20 Pressure test port X2, travel pump
21 Adjustment screw, hydraulic neutral position
22 Pressure test port R, travel pump case pressure
23 Pressure test port X2, travel pump
24 Pressure override valve 380 bar, vibration pump
25 Port T, flushing oil, travel motors
26 Pressure test port MA high pressure, forward trav-el
27 Pressure override valve 400 bar, travel pump
28 Travel pump
29 Leak oil connection T1 travel pump - T2 vibrationpump
30 Port G, charge oil from steering valves
31 Port T2, flushing oil, vibration motors
32 High pressure relief valve, forward travel, 440 bar
33 Charge pressure relief valve 25 bar, travel pump
34 High pressure relief valve, reverse travel, 440 bar35 High pressure relief valve, vibration, 400 bar
36 Connecting line, charge pressure supply to vibra-tion pump
37 High pressure test port, high frequency
38 Vibration pump
39 Port B, leak oil to cooler
40 Port E, leak oil, front travel motor
41 Port A, flushing/leak oil, travel/vibration pump
42 Port I, leak oil from brake valve
43 Port D, leak oil, rear travel motor44 Port F, leak oil from vibration shut-off valve
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2 Tests and adjustments
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2.1 Technical data
Fig. 1
Dimensions inmm
A B C D H H1 K L O W
BW 180 AD 3300 1920 815 1400 2400 30500 350 4700 60 1800
* BW 180 AD
Weights
Operating weight (CECE)with ROPS-cabin
kg 11870
Front axle load (CECE) kg 5935Rear axle load (CECE) kg 5935Static linear load, front/ rear
kg/cm 33/33
Dimensions
Steering/oscillation angle ± 20/8Track radius, inner/outer mm 3900/5700
Travel characteristics
Travel speed (1) km/h 0 ... 4Travel speed (2) km/h 0 ... 8Travel speed (3) km/h 0 ... 11Max. gradability without/ with vibration (soil de-pendent)
% 35/30
Drive
Engine manufacturer CumminsType 4 BT3.9-CCooling WaterNumber of cylinders 4Rated power ISO 9249IFN
kW 76
Nominal speed 1 rpm 2500low idle speed 1 rpm 950 ±50
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high idle speed 1 rpm 2725 ±55Electrical equipment V 12Battery V/AH 12/100Drive system hydrostaticDriven axles front + rear
Electrical equipment
Voltage supply V 12Battery V/AH 12/100Generator V/AHStarter V/kW 12/2,9
Travel pump
Manufacturer HydromatikType A4VG 71 EPSystem Axial piston/swash plateMax. displacement cm3 /rev. 71High pressure (pressurelimitation)
bar 440 ±10
High pressure (pressureoverride)
bar 400 ±10
Charge pressure bar 26 ±1
Drum drive motors
Manufacturer PoclainType MS 18 1CXSystem Radial pistonDisplacement cm3 /rev. 2100max. leak oil rate l/min 2
Vibration pump
Manufacturer HydromatikType A10VG 45 EZSystem Axial piston/swash plateMax. displacement cm3 /rev. 45Start-up pressure (pres-sure override)
bar 380 ±20
Operating pressure (soildependent)
bar approx. 100
Vibration motorsManufacturer HydromatikType A2FM 32System Axial piston/bent axleDisplacement cm3 /rev. 32max. leak oil rate l/min 1
Brakes
Service brake hydrostaticParking brake Releasing the mech.Brake releasing pressure bar
SteeringType of steering 2 point pivotSteering operation hydrostaticSteering angle ± 25
* BW 180 AD
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Crabwalk, lateral offset-ting of drum
mm 1220
Steering/charge pump
Manufacturer BoschType HY/ZFFS11/14+14System Tandem gear pumpDisplacement cm3 /rev. 2x14max. steering pressure bar 200 ±10
Steering valves
Manufacturer BucherType L.8SSystem Electrically proportional
Vibration system
Drive system hydrostaticFrequency 1/2 Hz 42/55Amplitude 1/2 mm 0,83/0,33
Filling capacities
Engine oil l approx. 9.5Fuel (diesel) l 170Sprinkler system l 900Hydraulic oil l approx. 60Coolant l approx. 20Exciter shaft tube l approx. 50
* The right for technical modifications remains reserved
* BW 180 AD
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2.2 Special tools
1. Vibration Reed frequency meter
BOMAG part-no.: 300 120 80
2. Engine RPM-meter
BOMAG part-no.: 059 711 12
3. Hydraulic test case
BOMAG part-no.: 007 610 03
4. Electric test case
BOMAG part-no.: 057 505 70
Fig. 1
Fig. 2
Fig. 3
Fig. 4
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5. Gear pump testing device
BOMAG part-no.: 007 610 05
6. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12V)
Fig. 5
Fig. 6
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2.3 Checking the rotation speeds
Special tools
Vibration Reed frequency meter, engien RPM-meter
Caution
Perform measurements at operating tempera-ture (40 °C).
1. Drive the machine with both drums on an elasticbase (rubber buffers) (Fig. 1).
Checking the engine speed
Note
If necessary, the engine speed may also bechecked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.2).
2. Measure the rotation speeds.
Nominal value low idle speed
950 ±50 rpm
3. Run the engine with maximum speed .
4. Measure the rotation speeds.
Nominal value high idle speed
2725 ±55 rpm
5. Switch on vibration of both drums.
Nominal value nominal speed
2500 rpm
Evaluation of test
If the nominal value is not reached, perform trou-ble shooting for the engine.
Fig. 1
Fig. 2
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Checking the vibrator shaft speed
1. Switch the vibration on at max. engine speed.
2. Measure the speed of the vibrator shaft, rest thetester on your thumb (Fig. 3).
Nominal value
high amplitude/ low frequency = 42 Hz, 2520 rpm
low amplitude/ high frequency = 55 Hz, 3300 rpm
Evaluation of test
If the nominal value is not reached, perform trou-ble shooting in the vibration circuit.
Fig. 3
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2.4 Pressure tests in the travel circuit
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Block the wheels with suitable chocks (Fig. 1).
2. Enter code number 500 on the display module(Fig. 2) to close the brake.
3. Connect a 600 bar pressure gauge (Fig. 3) to testport MA.
Fig. 1
Fig. 2
Fig. 3
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4. Connect a 600 bar pressure gauge (Fig. 4) to testport MB.
5. Connect a 60 bar pressure gauge (Fig. 5) to thecharge pressure test port.
6. Start the engine and run it with maximum speed.
7. Read high pressure and charge pressure gaug-es.
Nominal value
Charge pressure 26 ±1bar
High pressure 400 bar ±10 bar
Evaluation of test
If the nominal value is not reached, check thesteering/charge pump.
8. Move the travel lever quickly to forward and back-ward, read the pressure gauges.
Nominal value
Charge pressure min. 25 bar
High pressure 400 bar to both travel directions.
Evaluation of test
If the specified high pressure is not reached,check the travel pump.
If the charge pressure drops considerably duringthe high pressure test, check the components in-dividually.
Fig. 4
Fig. 5
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2.5 Checking / adjusting the neutral posi-tions of the travel pump
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Block the wheels with suitable chocks (Fig. 1).
2. Enter code number 500 on the display module(Fig. 2) to close the brake.
3. Connect a 600 bar pressure gauge (Fig. 3) eachto test ports MA and MB.
Fig. 1
Fig. 2
Fig. 3
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Mechanical neutral position
1. As a measure to avoid signal residues from thehydraulic neutral position connect both controlchambers X1 and X2 with a hose (Fig. 4).
2. Start the engine and run it with maximum speed.
3. Read the pressure gauges (Fig. 5).
Note
For a more exact adjustment repeat the test with60 bar pressure gauges
Nominal value
Both pressure gauges must show identical pres-sure, if necessary correct the mechanical neutralposition.
4. Adjust the neutral position (Fig. 6) so that bothpressure gauges show identical pressure (chargepressure).
Note
Equalize the dead range of the neutral position.
Fig. 4
Fig. 5
Fig. 6
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Hydraulic neutral position
1. Remove the hose connection between the controlchambers and screw the plugs back in (Fig. 7).
2. Start the engine and run it with maximum speed.
3. Read the pressure gauges (Fig. 8).
Note
For a more exact adjustment repeat the test with60 bar pressure gauges
Do not actuate the travel lever, since this may de- stroy the pressure gauges.
Nominal value
Both pressure gauges must show identical pres-sure (charge pressure), if necessary correct thehydraulic neutral position.
4. For this purpose loosen the clamping (Fig. 9).
Caution
Do not adjust the eccentric beyond the ± 90°position.
5. Adjust the neutral position on the eccentric (2), sothat both pressure gauges show identical pres-sure (charge pressure).
6. Retighten the clamping.
Fig. 7
Fig. 8
Fig. 9
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2.6 Check the setting of the high pressurerelief valves in the travel circuit
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Block the wheels with suitable chocks (Fig. 1).
2. Enter code number 500 on the display module(Fig. 2) to close the brake.
3. Connect a 600 bar pressure gauge (Fig. 3) eachto test ports MA and MB.
Fig. 1
Fig. 2
Fig. 3
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4. Turn the setscrew (Fig. 4) of the pressure over-ride completely in to block the valve.
5. Start the engine and run it with maximum speed.
Caution
Perform the following pressure test for max. 3seconds, otherwise pump damage caused byoverheating.
6. Move the travel lever quickly to both travel direc-tions and read the pressure gauges.
Nominal value
445 ±5 bar
Evaluation of test:
If the nominal value is only reached to one direc-tion, clean or replace the valve (Fig. 5) if neces-sary.
If the nominal value is not reached to both direc-tions check the travel pump, replace if necessary.
Adjusting the pressure override
Caution
To assure a reliable function of the pressureoverride, the pressure override valve must beadjusted 10% lower than the high pressure re-lief valve.
1. Turn the setscrew (Fig. 6) back out again, untilthe high pressure is limited to 400 ±10 bar whenthe drums are blocked.
Fig. 4
Fig. 5
Fig. 6
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2.7 Pressure measurements in the vibra-tion circuit
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Drive the machine with both drums on an elasticbase (rubber buffers) (Fig. 1).
2. Connect a 600 bar pressure gauge (Fig. 2) eachto test ports MA and MB.
3. Connect a 60 bar pressure gauge to the chargepressure test port.
4. Start the engine and run it with maximum speed.
5. Switch on vibration at high or low frequency andread the pressure gauge.
Nominal value
Charge pressure 26 ±1bar
Starting pressure 380 bar ±20 bar
Operating pressure (soil dependent) approx. 80... 100 bar
Evaluation of test
If the charge pressure drops, check the compo-nents individually.
If the starting pressure is not reached, check the
vibration pump.If the starting pressure is only reached for one fre-quency, check the high pressure relief valves.
Fig. 1
Fig. 2
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2.8 Check the setting of the high pressurerelief valves in the vibration circuit
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Drive the machine with both drums on an elasticbase (rubber buffers) (Fig. 1).
2. Connect a 600 bar pressure gauge (Fig. 2) eachto test ports MA and MB.
3. Turn the setscrew (Fig. 3) of the pressure over-ride completely in to block the valve.
4. Start the engine and run it with maximum speed.
Caution
Perform the following pressure test for max. 3seconds, otherwise pump damage caused byoverheating.
5. Switch on vibration at high or low frequency andread the start-up pressure on the pressuregauge.
Fig. 1
Fig. 2
Fig. 3
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Evaluation of test:
If the nominal value is only reached for one fre-quency, clean or replace the valve (Fig. 4) if nec-essary.
If the nominal value is not reached for both fre-
quencies check the travel pump, replace if neces-sary.
Nominal value
400 ±5 bar
Adjusting the pressure override
Caution
To assure a reliable function of the pressureoverride, the pressure override valve must beadjusted 10% lower than the high pressure re-lief valve.
1. Turn the setscrew (Fig. 5) back out again, so thatthe start-up pressure for the vibrator shafts is lim-ited to 380 bar.
Fig. 4
Fig. 5
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2.9 Checking / adjusting the vibrator shaftspeeds
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Drive the machine with both drums on an elasticbase (rubber buffers) (Fig. 1).
2. Start the diesel engine and shift the throttle leverto max. speed position.
3. Select the frequency and switch the vibration on.
4. Measure the speed of the vibrator shaft (Fig. 2),rest the tester on your thumb.
Nominal value
high amplitude/ low frequency = 42 Hz, 2520 rpm
low amplitude/ high frequency = 55 Hz, 3300 rpm
Evaluation of test
In case of deviations exceeding 10% determinethe cause, perform trouble shooting for engine /vibration circuit.
5. Adjust the speed on the corresponding adjust-ment screw (Fig. 3).
NoteTurning the adjustment screw in reduces thespeed, turning the screw out increases thespeed.
Fig. 1
Fig. 2
Fig. 3
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2.10 Checking the leakage rate of the vibra-tion motor
Special tools
Hydraulic test case
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
1. Drive the machine with both drums on an elasticbase (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Disconnect the leak oil and flushing oil hose (Fig.2) and close it with plugs.
4. Connect a leak oil hose to the leak oil port of themotor and hold it into a measuring vessel
5. Start the diesel engine and shift the throttle lever
to max. speed position.
6. Select the frequency and switch the vibration on.
7. Measure the leak oil over a period of one minute.
Caution
This measurement detects only the externalleak oil quantity.
Internal leaks, directly from the high to thelow pressure side, are not detected.
Nominal valuemax. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-place the vibration motor.
Fig. 1
Fig. 2
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2.11 Pressure test in steering circuit
Special tools
Hydraulic test case
NoteThe steering is actuated against an „electronic“
stop by the ESX-control. To actuate the steeringagainst the mechanical stop the ESX-controlmust be switched to the mode „Calibration of an- gle transducers“. After the pressure test the cali- bration process can be aborted.
Danger
Danger of squashing!
Do not stand in the range of rotation of the
pivot steering.
Caution
Perform measurements at operating tempera-ture of the hydraulic oil (40 °C).
Measuring the front steering pressure
1. Enter code number „600“ on display module (Fig.1).
The steering can now be actuated against themechanical stop.
2. Enter code number „620“ or switch the ignition offto stop this fuction.
3. Connect a 600 bar pressure gauge (Fig. 2) to thesteering pressure test port.
4. Start the engine and run it at idle speed.
Fig. 1
Fig. 2
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5. Adjust the front steering control (Fig. 3) and turnthe steering against an end stop.
6. Read the pressure gauge.
Nominal value
approx. 200 ±10 bar
Evaluation of test
If the nominal value is reached, check the steer-ing cylinder.
If the nominal value is not reached, check thesteering/charge pump.
Measuring the rear steering pressure
1. Enter code number „600“ on display module (Fig.4).
The steering can now be actuated against themechanical stop.
2. Enter code number „620“ or switch the ignition offto stop this fuction.
3. Connect a 600 bar pressure gauge to the rearsteering pressure test port (Fig. 5).
4. Start the engine and run it at idle speed.
5. Adjust the rear steering control (Fig. 6) and turnthe steering against an end stop.
6. Read the pressure gauge.
Nominal value
approx. 200 ±10 bar
Evaluation of test
If the nominal value is reached, check the steer-ing cylinder.
If the nominal value is not reached, check thesteering/charge pump.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
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2.12 Operation of display module for ESX-control
Description
The display module (Fig. 1) is used for the output
of fault codes and display values and for the inputof code numbers.
The module consists of a three digit display andtwo keys, F1 and F2.
Faults are indicated by flashing, if several faultshave occurred the displayed fault codes are alter-nately displayed in 3 second cycles. Display val-ues are permanently displayed.
Values from 000 ... 999 can be displayed. Highervalues are displayed in form of „---“. Negative val-ues are indicated by a minus symbol.
Entering code numbers
For calibration of the angle transducers and diag-nostics of the control inputs and outputs variouscode numbers must be entered on the displaymodule.
Code numbers are entered as follows:
1. Press both keys (F1 and F2) together for approx.two seconds.
The display shows „000“, whereby the first digit is
flashing. 2. Press key F1 as often as required to adjust the
flashing digit.
If key F1 is pressed again when figure „9“ is dis-played, the display will jump back to the value „0“.
3. Press key „F2“ to adjust the next digit.
The flashing display moves one digit to the right.
4. Press key F2 to change to the third digit and ad- just the desired value with the F1-key.
5. Press the F2-key again to confirm the adjusted
values and to execute the corresponding func-tion.
6. To cancel a display function you must either enterthe code number „000“ or switch the ignition off.
Fig. 1
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2.13 Driving against the closed brake
Note
On this machine the electric plug connection tothe brake valve must not be pulled off, because
the ESX-control would in this case detect a lineinterruption in the current path to the brake.
1. Enter code number „500“ on display module (Fig.1).
The brake will not be released when actuating thetravel lever.
The warning buzzer sounds to inform the opera-tor about this status.
2. Enter code number „501“ or switch the ignition offto stop this function.
Fig. 1
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2.14 Adjusting the machine type
Note
Only available from program version 16.
For simple control of the machine type, the ad-
justed machine type is displayed in the displaymodule for about three seconds after switchingthe ignition on.
Danger
Danger of injury!
Since the same control is used for all pivotsteered tandem rollers, it is strictly necessaryto specify the correct machine type when re-placing the ESX-control.
The machine must not be operated with awrong type setting.
Caution
Adjustments should only be made with theengine shut down.
1. Enter code number „725“ on display module (Fig.1).
The function „Change machine type“ is activated.
Table „Assignment machine type – machinetype code“
2. Select and enter the correct code from the table
above.
The display then permanently shows the enteredcode number.
Fig. 1
Machine type Serial-No. Code
BW 180 AD 101 870 00 .... 740BW 184 AD 101 870 30 .... 740BW 184 AD/AM 101 870 50 .... 740BW 170 AD 101 870 01 .... 731BW 170 AD 101 870 02 .... 733BW 170 AD/AM 101 870 11 .... 733BW 174 AD 101 870 31 .... 732BW 174 AC 101 870 41 .... 732BW 174 AD/AM 101 870 31 .... 732
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3. To store the machine type enter code number„726“ on the display module (Fig. 2).
When entering code “726“ the machine type codeis permanently stored.
NoteThe conversion process takes a few seconds.During this time the display permanently showsthe code number, the minus point flashes in an in- terval of one second.
Caution
During this time the ignition must not beswitched off! Otherwise the complete adjust-ment process must be repeated.
The new machine type will only become ac-
tive after the ignition has been switched offand on again!
By changing the machine type all settings aredeleted and must be reset as described here-under.
Fig. 2
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2.15 Calibration of the angle transducers
In order to assure a correct steering of the ma-chine, both angle transducers for front and reardrums must be calibrated.
NoteCalibration of the angle transducers is only nec- essary during initial start-up in the factory, after adisassembly or replacement of the angle trans- ducers and after changing the ESX-control.
Caution
Calibration must always be performed forboth drums.
Calibration is only possible in steering modeselection „Steering front“ and „Steering
rear”. With any other steering selection thisfunction is not active. When changing to an-other, unpermitted steering mode during theadjustment, the complete adjustment proce-dure must be repeated.
During the calibration process the machinemust not drive faster than 3 km/h, as other-wise the complete adjustment proceduremust be repeated.
The new values will only become active afterthe ignition has been switched off and onagain.
1. Enter code number „600“ on display module (Fig.1).
This code number activates the function „Calibra-tion of the angle sensors“. In this case the displaypermanently shows the value „600“.
Calibrating the front stops
1. Steer the front drum (Fig. 2) to the left hand stop.
2. When the stop is reached enter code number601.
In this case the display permanently shows thevalue „601“.
3. Steer the front drum to the right hand stop.
4. When the stop is reached enter code number603.
In this case the display permanently shows thevalue „603“.
Fig. 1
Fig. 2
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Calibrating the rear stops
1. Steer the rear drum (Fig. 3) to the left hand stop.
2. When the stop is reached enter code number611.
In this case the display permanently shows the
value „611“.
3. Steer the rear drum to the right hand stop.
4. When the stop is reached enter code number613.
In this case the display permanently shows thevalue „613“.
Calibrating the straight ahead posi-tion
1. Steer the front drum (Fig. 4) to straight ahead po-
sition. 2. When the stop is reached enter code number
602.
In this case the display permanently shows thevalue „602“.
3. Steer the rear drum to straight ahead position.
4. When the stop is reached enter code number612.
In this case the display permanently shows thevalue „612“.
Note
The function „Calibration“ is automatically termi- nated after all codes have been entered.
If the function „Calibration“ is to be aborted pre- maturely, enter code 620 and switch off the igni- tion.
5. Switch the ignition off and on again to activate thenew values.
Fig. 3
Fig. 4
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2.16 Adjusting the angle transducers
In order to assure an optimal function of the posi-tion detection in the steering system, both angletransducers for front and rear drums must be ad- justed.
This adjustment determines the position of theangle transducers to the transom bed.
Note
Calibration of the angle transducers is only re- quired during initial start-up in the factory and af- ter disassembly or replacement of the angletransducers.
Caution
For the adjustment the angle transducers
must have been calibrated, as otherwise thestraight ahead position will not be reached(see previous section).
Even if only one angle transducer has beenadjusted both transducer must be adjustedanew (see previous section).
1. Align both drums to straight ahead position.
Note
In order to bring both drums to straight ahead po- sition deactivate the crab-walk (green light goes
out) and change from „steering front“ to „steeringrear“ and back to „steering front“ while driving..
This utilizes the automatic neutral setting of thedrums when changing the steering mode.
Steering must be stopped when switching overand it must be assured that the automatic neutralsetting of the drum is completed.
Then stop steering, stop the machine and shutdown the engine.
Checking the front adjustment
Caution
For the following steps shut the engine downand switch the ignition off.
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1. Enter code number „250“ on display module (Fig.1) and read the following display.
Nominal value:
117 to 123, ideal value 120
Evaluation of display
If the value is outside this range, the angle trans-ducer must be adjusted.
Adjusting the angle transducer
1. Loosen fastening screws 3 (Fig. 2) in the slots ofangle transducer (2) and turn the transducer, until
the value is in the permissible range.
Note
If the adjustment range in the slots is not suffi- cient, loosen coupling 2 (Fig. 2) between trans- ducer and transom bed and turn also.
2. Retighten all fastening screws and check the dis-play module once again.
Caution
Even if only one angle transducer has been
adjusted both transducer must be adjustedanew (see previous section).
Check the rear adjustment
Caution
For the following steps shut the engine downand switch the ignition off.
1. Enter code number „260“ on display module (Fig.3) and read the following display.
Nominal value:
117 to 123, ideal value 120
Evaluation of display
If the value is outside this range, the angle trans-ducer must be adjusted. (see previous descrip-tion).
Fig. 1
Fig. 2
Fig. 3
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2.17 Automatic detection of step currentsfor the steering valves
For a sensitive and exact control of the steeringthe step currents must be determined for the fourcontrol solenoids of both steering valves. The
step currents are automatically adjusted after en-tering the code number, so that no additional me-ter is required.
After entering the respective code number thecurrent is increased by the control solenoid in 5mA steps. After each current increase the systemwaits for two seconds. If the ESX-control has de-tected a considerable angle change of the drumafter the expiration of the waiting time, the stepcurrent is reached.
In order to enhance the measuring result themeasurement is performed three times. The final
step current is the mean value of the three meas-urements. This step current is automaticallystored and is valid from the next time the machineis started.
Note
The determination of the step currents is only re- quired during initial start-up in the factory, afterreplacing a steering valve, the steering valve con- trol or after changing the ESX-control
The measurement is identical for all solenoids.
Caution
For the determination of the step current parkthe machine ón firm and level ground.
The steering system must be thoroughly bledbefore performing this measurement.
Align the drum to straight ahead position.
The new values will only become active afterthe ignition has been switched off and onagain.
Danger
Danger of injury!
During the measuring process the machinecannot be steered, the machine should there-fore not be driven during the detection of thestep current.
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1. Start the engine and run it with maximum speed(Fig. 1).
2. Release the brake (Fig. 2).
3. Enter code number „630“ on display module (Fig.
3).This code activates the function „Automaticmeasurement of step currents for the steeringvalves“. In this case the display shows the value„630“.
Each of the four measurements for the four con-trol solenoids must be started separately by en-tering a code number.
The code number for the four control solenoids isas follows:
4. Enter the corresponding code number for stepcurrent detection.
During the measurement the present control cur-rent is displayed (display x 10 = current [mA]).
Once the measuring process is finished the dis-play value „000“ appears for two seconds, thenthe code number „630“ is displayed again. The
next measurement can be started. 5. After all four step currents have been measured
shut down the engine to terminate the function.
The new step currents apply after the next start.
Fig. 1
Fig. 2
Fig. 3
Solenoid Code No.
Control front left 631Control front right 632Control rear left 633Control rear right 634
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2.18 Adjusting the type of travel rangeswitch
For the selection of the travel speed a 3-stageswitch (Fig. 1) is installed as standard.
A 24 stage switch (Fig. 2) can alternatively be in-
stalled.
The switch type must be entered using the re-spective code, so that the ESX-control is able toevaluate the travel speed switch correctly.
Note
The 3-stage switch is set as standard value, i.e. astandard machine does not require any adjust- ments.
Caution
Adjustments should only be made with theengine shut down.
The new values will only become active afterthe ignition has been switched off and onagain.
Adjusting the machine for the 24-stage switch
1. Enter code number „650“ on display module (Fig.3).
This code activates the function „Parameterchange speed range switch“. In this case the dis-play shows the value „650“.
Note
This code number must be entered before the fol- lowing step can be performed.
Fig. 1
Fig. 2
Fig. 3
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2. Enter code number „652“ on display module (Fig.4) to select the „24-stage switch“.
The display reading disappears.
3. Switch off the ignition.
With the next start the 24-stage switch is evaluat-
ed.
Adjusting the machine for the 3-stageswitch
1. Enter code number „650“ on display module (Fig.5).
This code activates the function „Parameterchange speed range switch“. In this case the dis-play shows the value „650“.
Note
This code number must be entered before the fol- lowing step can be performed.
2. Enter code number „651“ on display module (Fig.6) to select the „3-stage switch“.
The display reading disappears.
3. Switch off the ignition.
With the next start the 3-stage switch is evaluat-ed.
Fig. 4
Fig. 5
Fig. 6
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2.19 Resetting the step currents in the trav-el system
This function allows the resetting of step currentsin the travel system to their minimum value.
This measure avoids that the travel system is
controlled with a too high step current.
Note
This measure is only required after replacing thetravel pump control or the complete travel pump.It helps to move the machine before performingthe function „Automatic detection of step cur- rents“.
This function does not need to be performed afterreplacing the ESX-control, because a new ESXcontrol is always set for minimum step current.
Caution
During the input the engine must not be run-ning.
The new values will only become active afterthe ignition has been switched off and onagain.
1. Enter code number „665“ on display module (Fig.1).
This code activates the function „Resetting thestep currents in the travel system“. In this case
the display shows the value „665“.
2. Enter code number „666“ on display module (Fig.2).
Eith this code the step current is reset to the min-imum value (350 mA).
3. Switch off the ignition.
The minimum step currents apply after the nextstart.
Fig. 1
Fig. 2
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2.20 Automatic detection of step currentsin the travel system
For a sensitive and exact control of the travel sys-tem the step currents must be determined forboth travel directions. The step currents are auto-
matically adjusted after entering the codenumber, so that no additional meter is required.
After entering the respective code number thecurrent is increased by the control solenoid in 5mA steps, starting with 350 mA. After each cur-rent increase the system waits for three seconds.If the ESX-control has detected a considerablemovement of the drum after the expiration of thewaiting time, the step current is reached.
In order to enhance the measuring result themeasurement is performed three times. The finalstep current is the mean value of the three meas-
urements. This step current is automaticallystored and is valid from the next time the machineis started.
Note
The determination of the step currents is only re- quired during initial start-up in the factory, afterreplacing the travel pump, the travel pump controlor after changing the ESX-control
The measurement is identical for both travel di- rections.
Caution
For the determination of the step current parkthe machine ón firm and level ground.
Ensure sufficient space in front of and behindthe machine (approx. 10 m), because the ma-chine will move during the measuring proc-ess.
Align the drum to straight ahead position.
The new values will only become active afterthe ignition has been switched off and on
again.
Danger
Danger of injury!
During the measuring process the machinewill start to move when the step current isreached.
Do not leave the machine during the measur-ing process.
The areas in front of and behind the machine
must be free of persons.Before starting the measurement it must beassured that the speed sensor on the frontright hand drum drive motor works correctly.
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The measurement must not be performed ifthe sensor is defective.
1. Align the seat in forward direction.
2. Switch off the Speed Control.
3. Start the engine and run it with maximum speed
(Fig. 1).
Checking the function of the speedsensor
1. Enter code number „102“ on display module (Fig.2).
This code shows the number of travel pulses ofthe sensor.
2. Move the machine to both directions.
The displayed value must change when the ma-chine is moving.
Detecting the step currents
Danger
Danger of accident!
After entering the code number the machine
can no longer be controlled with the travel le-ver. The function of the travel lever is only re-established after the engine is shut down andrestarted.
In case of a danger the machine can bestopped by shifting the travel lever to neutralposition. In this case the complete measuringprocess must be repeated.
Fig. 1
Fig. 2
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1. Enter code number „660“ on display module (Fig.3).
This code activates the function „Automaticmeasurement of step currents in the travel sys-tem“. In this case the display shows the value„660“.
Each of the four measurements for the four con-trol solenoids must be started separately by en-tering a code number.
The code number for both control solenoids is asfollows:
Each of the four measurements for the four con-trol solenoids must be started separately by en-tering a code number.
2. Enter the corresponding code number for stepcurrent detection according to the table.
3. Move the travel lever (Fig. 4) forward or backwardas required by the entered code number.
During the measurement the present control cur-rent is displayed (display x 10 = current [mA]).
Once the measuring process is finished the dis-play value „000“ appears, then the code number„660“ is displayed again. The next measurementcan be started.
4. After both step currents have been measuredshut down the engine to terminate the function.
The new step currents apply after the next start.
Fig. 3
Travel direction Code No.
Forward 661Backward 662
Fig. 4
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2.21 Showing stored faults
Note
Besides stored faults, current faults are also dis- played.
Switching the function on
1. Enter code number „700“ on display module (Fig.1).
The function “Show stored faults“ is switched on.
Switching the function off
1. Enter code number „701“ on display module (Fig.2).
The function “Show stored faults“ is switched off.
Fig. 1
Fig. 2
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2.22 Deleting stored faults
Note
Stored faults can only be deleted when the en- gine is not running.
1. Enter code number „710“ on display module (Fig.1).
All stored faults are deleted.
Fig. 1
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3 Flushing
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3.1 Special tool:
1. Filling and filtering unit with oil bag
BOMAG part-no.: 007 610 01
2. Filter element
BOMAG part-no.: 079 930 35
3. Flushing filter
BOMAG part-no.: 007 000 01
4. Filter element 1µ
BOMAG part-no.: 079 930 52
5. Flushing hose 25S - 20S (2 pieces)
BOMAG part-no.: 055 509 19
6. Screw socket R1“ -- 25S (2 pieces)
BOMAG part-no.: 055 400 52
7. Double-end union 20 S
BOMAG part-no.: 055 426 17
8. Double-end union 16 S
BOMAG part-no.: 055 426 16
Fig. 1
Fig. 2
Fig. 3
Fig. 4
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9. Reducing fitting 25S - 20 S
BOMAG part-no.: 055 422 98
10. Elbow 20S
BOMAG part-no.: 055 421 37
11. Elbow 16S
BOMAG part-no.: 055 421 36
Fig. 5
Fig. 6
Fig. 7
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Fig. 1 Schematic for front travel system
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After changing a component
1. Always flush the closed circuit.
Caution
Solid particles remaining in the circuit willdamage the components again within ashort period of time.
In case of excessive oil contamination
(abrasion)
1. Open and clean all other components.
2. If necessary replace the hydraulic hoses.
3. Flush also the vibration circuit.
Befor flushing
1. Change the hydraulic oil filter element.
2. Clean the inside of the hydraulic oil tank.
3. Filter the hydraulic oil with the filtering unit.
Note
For filtering use the filling and filtering unit.Pump the tank contents through a fine filter intothe oil bag or a clean container.
Environment
Catch hydraulic oil and dispose of environ-mentally! For filling use also the filteringunit.
Change the oil:in case of excessive contamination,
oil discoloration,
oil change interval almost reached.
Flushing filter installation (Fig. 1)
1. Connect the flushing filter outlet "OUT" with thetravel pump.
2. Connect the flushing inlet „IN“ with the hosefrom the front drum drive motor.
Caution
The flushing filter must be installed in thelow pressure side in the return flow to the
pump, so that only cleaned oil will enter thetravel pump.
With the connection shown in the illustra-tion the travel pump must therefore be actu-ated to reverse direction.
Flushing of the hoses
1. Take the front drum drive motor out of the cir-cuit, for this purpose join the high pressure linesat the drum drive motor together.
Flushing the complete system
1. Reconnect the drum drive motor.
2. Jack the front drum up for flushing.
Bleeding
1. Always bleed the closed hydraulic circuit if lineshad been removed or connected.
1 Travel pump
2 Elbow 20S
3 Flushing fi lter
4 Screw socket 1“ - 25S
5 Flushing hose 25S - 20S
6 Front drum drive motor
7 Double end union 20S
8 Elbow 20S
9 Double end union 20S
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Fig. 1 Schematic of rear travel system
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After changing a component
1. Always flush the closed circuit.
Caution
Solid particles remaining in the circuit willdamage the components again within ashort period of time.
In case of excessive oil contamination
(abrasion)
1. Open and clean all other components.
2. If necessary replace the hydraulic hoses.
3. Flush also the vibration circuit.
Befor flushing
1. Change the hydraulic oil filter element.
2. Clean the inside of the hydraulic oil tank.
3. Filter the hydraulic oil with the filtering unit.
Note
For filtering use the filling and filtering unit.Pump the tank contents through a fine filter intothe oil bag or a clean container.
Environment
Catch hydraulic oil and dispose of environ-mentally! For filling use also the filteringunit.
Change the oil:in case of excessive contamination,
oil discoloration,
oil change interval almost reached.
Flushing filter installation (Fig. 1)
1. Connect the flushing filter outlet "OUT" with thetravel pump.
2. Connect the flushing inlet „IN“ with the hosefrom the rear drum drive motor.
Caution
The flushing filter must be installed in thelow pressure side in the return flow to the
pump, so that only cleaned oil will enter thetravel pump.
With the connection shown in the illustra-tion the travel pump must therefore be actu-ated to reverse direction.
Flushing of the hoses
1. Take the rear drum drive motor out of the cir-cuit, for this purpose join the high pressure linesat the drum drive motor together.
Flushing the complete system
1. Reconnect the drum drive motor.
2. Jack the rear drum up for flushing.
Bleeding
1. Always bleed the closed hydraulic circuit if lineshad been removed or connected.
1 Travel pump
2 Elbow 20S
3 Elbow 20S
4 Double end union 20S
5 Rear drum drive motor
6 Flushing filter
7 Screw socket 1“ - 25S
8 Flushing hose 25S - 20S
9 Double end union 20S
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3.4 Flashing the travel circuit
Cleaning the hydraulic oil tank
Environment
Catch hydraulic oil and dispose of environ-mentally!
1. Pump the hydraulic oil from the hydraulic oil tankinto a clean container or an oil bag using the fillingand filtering unit.
2. Mark all hoses (Fig. 1) and disconnect them fromthe tank cover.
3. Unscrew the fastening screws for the cover andremove the cover.
4. Clean the hydraulic oil tank thoroughly from in-side, reassemble cover and hoses.
Filter installation for flushing of thefront travel circuit
CautionBefore installing the flushing filter check hos-es and connections for cleanliness, clean ifnecessary.
1. Disconnect the high pressure hose (Fig. 2) fromthe travel pump.
Fig. 1
Fig. 2
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2. Connect the flushing hose (Fig. 3) from filter out-let port „OUT“ to the travel pump using an anglefitting.
3. Connect the filter inlet port „IN“ (Fig. 4) with thedisconnected high pressure hoses from the travelpump using a connecting socket.
4. Flushing hose (Fig. 5) from filter port „IN“ must be
connected with the high pressure hose from thetravel pump (port A).
5. Flushing hose from filter port „OUT“ must be con-nected with the travel pump (port A).
6. Unscrew the high pressure hoses 3 (Fig. 6) fromthe front drum drive motor and join them togetherwith angle fittings (2) and socket (1).
7. Fill the hydraulic oil tank again with the filling andfiltering unit.
Note
If the hydraulic oil change interval is almostreached use new hydraulic oil.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
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Bleeding the travel circuit
1. Pull the plug (Fig. 7) off the engine shut-down so-lenoid, so that the engine cannot start.
2. Secure the drums with chocks .
Environment
Catch hydraulic oil and dispose of environ-mentally.
3. Install pressure test hoses to the charge pressuretest port and to the high pressure test ports in thetravel system.
4. Hold the open ends of the pressure test hoses(Fig. 8) into a container.
5. Crank the engine approx. 30 seconds with thestarter motor. Wait one minute and repeat thisprocedure, until oil starts to run out from the pres-sure test hoses.
6. Disconnect the pressure test hoses from the highpressure test ports.
7. Reconnect the plug to the engine shut-down so-lenoid.
8. Connect a 60 bar pressure gauge to the chargepressure test hose (Fig. 9) and run the enginemax. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-cedure, until the pressure gauge shows a con-stant charge pressure.
Caution
Move the travel lever only to travel directionbackward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-tion.
10. For bleeding shift travel lever (Fig. 10) approx. 1/ 3 in travel direction backward while running theengine with idle speed.
11. After running the engine 1 to 2 minutes with idlespeed pause for approx. one minute.
Fig. 7
Fig. 8
Fig. 9
Fig. 10
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Note
This waiting time is necessary to allow air bub- bles to escape through the leak oil return line.
Repeat this measure, until the charge pressurereading immediately drops to zero when shutting
the engine down.In this case the closed travel circuit is properlybled.
Flushing the lines of the front travelcircuit
Caution
Move the travel lever only to travel directionbackward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-
tion.
1. Shift the travel lever (Fig. 11) to travel directionbackward.
2. Perform the flushing process at various enginespeeds for approx. 15 minutes.
3. Shut down the engine.
Environment
Catch hydraulic oil and dispose of environ-mentally!
4. Reconnect the high pressure hoses to the frontdrum drive motor.
Flushing the front drum drive motor
Danger
Danger of squashing!
Do not lay under the jacked up machine. 1. Jack up the front of the machine (Fig. 12), so that
the drum can rotate freely.
2. Secure the rear drum with chocks .
Fig. 11
Fig. 12
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Caution
Move the travel lever only to travel directionbackward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-tion.
3. Shift the travel lever (Fig. 13) to travel directionbackward.
4. Perform the flushing process at various enginespeeds for approx. 15 minutes.
5. Shut down the engine.
Filter installation for flushing of therear travel circuit
CautionBefore installing the flushing filter check hos-es and connections for cleanliness, clean ifnecessary.
1. Disconnect the high pressure hose (Fig. 14) fromthe travel pump.
2. Connect flushing hose 1 (Fig. 15) from filter outletport „OUT“ to the travel pump using an angle fit-ting.
3. Connect flushing hose (2) from filter inlet port „IN“with the disconnected high pressure hoses from
the travel pump using a connecting socket.
Fig. 13
Fig. 14
Fig. 15
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4. Flushing hose (Fig. 16) from filter port „IN“ mustbe connected with the high pressure hose fromthe travel pump (port A).
5. Flushing hose from filter port „OUT“ must be con-nected with the travel pump (port A).
6. Unscrew the high pressure hoses 3 (Fig. 17) fromthe rear drum drive motor and join them togetherwith angle fittings (2) and socket (1).
7. Fill the hydraulic oil tank again with the filling andfiltering unit.
Note
If the hydraulic oil change interval is almostreached use new hydraulic oil.
Bleeding the travel circuit
1. Pull the plug (Fig. 18) off the engine shut-downsolenoid, so that the engine cannot start.
2. Secure the drums with chocks .
Environment
Catch hydraulic oil and dispose of environ-mentally.
3. Install pressure test hoses to the charge pressuretest port and to the high pressure test ports in thetravel system.
4. Hold the open ends of the pressure test hoses(Fig. 19) into a container.
5. Crank the engine approx. 30 seconds with thestarter motor. Wait one minute and repeat thisprocedure, until oil starts to run out from the pres-sure test hoses.
6. Disconnect the pressure test hoses from the highpressure test ports.
7. Reconnect the plug to the engine shut-down so-lenoid.
Fig. 16
Fig. 17
Fig. 18
Fig. 19
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8. Connect a 60 bar pressure gauge to the chargepressure test hose (Fig. 20) and run the enginemax. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-cedure, until the pressure gauge shows a con-stant charge pressure.
Caution
Move the travel lever only to travel directionbackward, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-tion.
10. For bleeding shift travel lever (Fig. 21) approx. 1/ 3 in travel direction backward while running theengine with idle speed.
11. After running the engine 1 to 2 minutes with idlespeed pause for approx. one minute.
Note
This waiting time is necessary to allow air bub- bles to escape through the leak oil return line.
Repeat this measure, until the charge pressurereading immediately drops to zero when shuttingthe engine down.
In this case the closed travel circuit is properlybled.
Fig. 20
Fig. 21
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Flushing the lines of the rear travelcircuit
Caution
Move the travel lever only to travel direction
backward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-tion.
12. Shift the travel lever (Fig. 22) to travel directionbackward.
13. Perform the flushing process at various enginespeeds for approx. 15 minutes.
14. Shut down the engine.
Environment
Catch hydraulic oil and dispose of environ-mentally!
15. Reconnect the high pressure hoses to the reardrum drive motor.
16. Repeat the bleeding process.Fig. 22
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Flushing the rear drum drive motor
Danger
Danger of squashing!
Do not lay under the jacked up machine.
1. Jack up the rear of the machine (Fig. 23), so thatthe drum can rotate freely.
2. Secure the front drum with chocks .
Caution
Move the travel lever only to travel directionbackward, as otherwise the flushing filter willbe subjected to oil flow from the wrong direc-tion.
3. Shift the travel lever (Fig. 24) to travel directionbackward.
4. Perform the flushing process at various engine
speeds for approx. 15 minutes. 5. Shut down the engine.
Function test
1. Check the hydraulic oil level (Fig. 25) in the tank,fill up if necessary.
2. Cleaning the machine
3. Perform a test drive, load the travel system in for-ward and reverse, e.g. by driving uphill or startingon a gradient.
4. Check all ports and connections for leak tightness(visual inspection).
Servicing the flushing filter kit
1. Replace the filter element of the flushing filterwhen the red control pin of the contamination in-dicator is pressed out during the filtering process.
Fig. 23
Fig. 24
Fig. 25
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Note
This is also possible with very cold oil.
2. Clean hoses and connections and store the flush-ing kit in a clean and protected environment.
3. Change the flushing filter element of the filling
and filtering unit when the red control pin of thecontamination indicator is pressed out.
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Fig. 1
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After changing a component
1. Always flush the closed circuit.
Caution
Solid particles remaining in the circuit willdamage the components again within ashort period of time.
In case of excessive oil contamination
(abrasion)
1. Open and clean all other components.
2. If necessary replace the hydraulic hoses.
3. Flush also the vibration circuit.
Befor flushing
1. Change the hydraulic oil filter element.
2. Clean the inside of the hydraulic oil tank.
3. Filter the hydraulic oil with the filtering unit.
Note
For filtering use the filling and filtering unit.Pump the tank contents through a fine filter intothe oil bag or a clean container.
Environment
Catch hydraulic oil and dispose of environ-mentally! For filling use also the filteringunit.
Change the oil:in case of excessive contamination,
oil discoloration,
oil change interval almost reached.
Flushing filter installation (Fig. 1)
1. Connect the flushing filter outlet "OUT" with thevibration pump.
2. Connect the flushing inlet „IN“ with the hosefrom the shut-off valve.
Caution
The flushing filter must be installed in thelow pressure side in the return flow to the
pump, so that only cleaned oil will enter thetravel pump.
For the connection schematic shown herethe vibration must always be filtered with„low frequency / high amplitude“.
Flushing of the hoses
1. Take the vibration motor out of the circuit, forthis purpose join the high pressure lines togeth-er.
Flushing the complete system
1. Reconnect the vibration motor and pull it out ofthe coupling for flushing.
Bleeding
1. Always bleed the closed hydraulic circuit if lineshad been removed or connected.
1 Shut-off valve
2 Elbow 20S
3 Double end union 20S
4 Vibration pump
5 Flushing hose 25S - 20S
6 Screw socket 1“ - 25S
7 Flushing filter
8 Rear vibration motor
9 Front vibration motor
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3.6 Flushing the vibration circuit
Cleaning the hydraulic oil tank
Environment
Catch hydraulic oil and dispose of environ-mentally!
1. Pump the hydraulic oil from the hydraulic oil tankinto a clean container or an oil bag using the fillingand filtering unit.
2. Mark all hoses (Fig. 1) and disconnect them fromthe tank cover.
3. Unscrew the fastening screws for the cover andremove the cover.
4. Clean the hydraulic oil tank thoroughly from in-side, reassemble cover and hoses.
Filter installation for flushing of the vi-bration drive
CautionBefore installing the flushing filter check hos-es and connections for cleanliness, clean ifnecessary.
1. Disconnect the high pressure hose (Fig. 2) fromthe vibration pump.
Fig. 1
Fig. 2
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2. Connect flushing hose 3 (Fig. 3) to high pressurehose (5) using connecting socket (4).
3. Connect flushing hose (2) to the vibration pumpusing elbow fitting (1).
4. Connect the flushing hose (Fig. 4) from the highpressure hose to flushing filter inlet „IN“.
5. Connect the flushing hose from the vibration
pump to the flushing filter outlet „OUT“.
6. Disconnect hydraulic hoses 2 (Fig. 5) from both
vibration motors and join them together withsocket (1).
7. Fill the hydraulic oil tank again with the filling andfiltering unit.
Note
If the hydraulic oil change interval is almostreached use new hydraulic oil.
Bleeding the vibration circuit
1. Pull the plug (Fig. 6) off the engine shut-down so-lenoid, so that the engine cannot start.
2. Secure the drums with chocks .
Environment
Catch hydraulic oil and dispose of environ-mentally.
3. Install pressure test hoses to the charge pressure
test port and to the high pressure test ports in thevibration system.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
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4. Hold the open ends of the pressure test hoses(Fig. 7) into a container.
5. Crank the engine approx. 30 seconds with thestarter motor. Wait one minute and repeat thisprocedure, until oil starts to run out from the pres-sure test hoses.
6. Disconnect the pressure test hoses from the highpressure test ports.
7. Reconnect the plug to the engine shut-down so-lenoid.
8. Connect a 60 bar pressure gauge to the chargepressure test hose (Fig. 8) and run the enginemax. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-cedure, until the pressure gauge shows a con-stant charge pressure.
Caution
Use only low frequency, as otherwise theflushing filter will be subjected to oil flow fromthe wrong direction.
10. For bleeding switch on low frequency (Fig. 9) forboth drums at idle speed.
11. After running the engine 1 to 2 minutes pause forapprox. one minute.
Note
This waiting time is necessary to allow air bub- bles to escape through the leak oil return line.
Repeat this measure, until the charge pressurereading immediately drops to zero when shuttingthe engine down.
In this case the closed travel circuit is properlybled.
Fig. 7
Fig. 8
Fig. 9
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Flushing the hoses in the vibrationcircuit
Caution
Use only low frequency, as otherwise the
flushing filter will be subjected to oil flow fromthe wrong direction.
1. For bleeding switch on low frequency (Fig. 10) forboth drums at full engine speed.
2. Run the flushing procedure for approx. 10 min-utes. Switch the vibration on and off at intervals ofapprox. 30 seconds.
3. Shut down the engine.
Environment
Catch hydraulic oil and dispose of environ-mentally!
4. Reconnect both high pressure hoses to both vi-bration motors.
Flushing the vibration motors
1. Unscrew the fastening screws for both vibrationmotors and pull the motors out of their couplings(Fig. 11).
Caution
Use only low frequency, as otherwise theflushing filter will be subjected to oil flow from
the wrong direction. 2. For bleeding switch on low frequency (Fig. 12) for
both drums at full engine speed.
3. Run the flushing procedure for approx. 10 min-utes. Switch the vibration on and off at intervals ofapprox. 30 seconds.
4. Shut down the engine.
Fig. 10
Fig. 11
Fig. 12
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Function test
1. Check the hydraulic oil level (Fig. 13) in the tank,fill up if necessary.
2. Cleaning the machine
3. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or startingon a gradient.
4. Check all ports and connections for leak tightness(visual inspection).
Servicing the flushing filter kit
1. Replace the filter element of the flushing filter
when the red control pin of the contamination in-dicator is pressed out during the filtering process.
Note
This is also possible with very cold oil.
2. Clean hoses and connections and store the flush-ing kit in a clean and protected environment.
3. Change the flushing filter element of the fillingand filtering unit when the red control pin of thecontamination indicator is pressed out.
Fig. 13
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4 Trouble shooting
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4.1 General
General notes on trouble shooting in hy-draulic systems
The following tests are performed for fault diagnosticsand should enable you to encircle a fault in the hy-draulic system.
At this point it is assumed that there is no fault in theelectric system, i.e. trouble shooting in the electricsystem has already been performed.
In some cases these tests may also be conducted toidentify faults on hydraulic components of the powertransmission system.
On the basis of preliminary tests the individual meas-urements have the purpose to limit the cause of thefault first of all to a general area and then to determineexactly which oil circuit or hydraulic component is notworking correctly.
Important points for trouble shooting andfault rectification
Danger
Danger of injury!
Do not touch rotating parts of the engine.
When working on the travel pump and performingtests in the travel circuit block the drums withsuitable wheel chocks.
Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You shouldtherefore relieve the pressure in the system be-fore disconnecting any lines. Before repressuriz-ing the system make sure that all line connectionsand ports are in perfect condition.
When being injured by hydraulic oil consult a phy-sician immediately, as otherwise this may causesevere infections.
Caution
It is not recommended to open or repair hydraulic
units and components without comprehensiveknowledge.
Risk of damage to pressure gauges if incorrectlyconnected.
When performing trouble shooting it is assumed thatthe machine is correctly equipped and connected, thatconnections and hoses are free of faults and that set-screws have not been deadjusted without permission.
Progressive tests drawn up in the trouble shooting di-agram lead to the detection of faults and their rectifi-cation by trained personnel.
Ensure strict cleanliness, clean ports and fittingsbefore disconnecting.
Cover all openings and ports or close with plugs.
Check the hydraulic oil level before and after thework.
Use only clean oil according to specification.
Check the hydraulic system for leaks, find and rec-tify the cause.
Ensure strict cleanliness, clean ports and fittingsbefore disconnecting.
Fill new hydraulic units with hydraulic oil beforestarting operation.
After changing a component thoroughly flush andbleed the hydraulic system.
AS far as possible conduct all measurements at op-erating temperature 40 ... 50 °C.
After changing a component check charge and highpressure, if necessary check the rotational speed.
Hydraulic hoses
Danger
Danger of injury
Hydraulic hoses must be visually inspected atregular intervals.
Hydraulic hoses must be immediately replaced if:
the outer layer is damaged down to the inlay (e.g.chafing, cuts, cracks, etc.)
the outer layer is brittle (formation of cracks in the
hose material) the hose shows deformations in pressurized and
depressurized condition, which do not comply withthe genuine shape of the hydraulic hose
the hose shows deformations in bends, e.g.squeezing, buckling, layer separation, formation ofblisters
the hose is leaking
the hydraulic hose has separated from the fitting
the fitting shows corrosion that impairs both function
and strength the fitting is deformed in a way that both function
and strength are affected
the storage time and utilization period has expired.
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4.2 Trouble shooting diagram
The machine drives with the travel lever in „NEUTRAL“
Neutral position
OK?
no
yes
Check the mechanical neutral position
- Enter code number 500 to close the brake
- Connect control chamber ports X1 and X2 with
a hose
Adjust the hydraulic neutral position
- Remove the hose connecting X1 and X2
- Run the engine with maximum speed.
- Adjust the hydraulic neutral position so that
identical pressures are indicated at MA and
MB (charge pressure)
Adjusting the mechanical neutral position
- Connect 600 bar pressure gauges to MA and
MB
- Run the engine with maximum speed.
- Adjust the mechanical 0-position so that identi-
cal pressures are indicated at MA and MB
(charge pressure)
- For a more exact adjustment repeat the testwith 60 bar pressure gauges
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Machine does not drive / insufficient travel performance
High pressureOK?
no
yes
Brake valve
OK?
yes
no Replace the brake valve
Check high and charge pressure
- Connect 600 bar pressure gauges to the high pressure testport
- Connect a 60 bar pressure gauge to the charge pressure test
port
- Start the engine and run it with maximum speed
- Drive the machine against the closed brake, for this purpose
enter code number 500, actuate the travel lever for a moment
and read the pressure gauge
Nominal value:
High pressure approx. 400 bar ±10 bar,charge pressure approx. 26 bar
Check the brake releasing pressure
- Install a 60 bar pressure gauge to the
brake releasing line
- Start the engine and check whether
the brake valve opens when the
brake is released
Nominal value:
approx. 26 bar (charge pressure)
Mechanical fault,
blocked drive
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Charge
pressure OK?
yes
no
Check the front steering pressure
- Connect a 600 bar pressure gauge to
the steering pressure test port
- Enter code number 600
- Pull the plug off the starter solenoidand crank the engine with the starter
- Turn the front steering against one of
the end stops and read the pressure
gauge
Nominal value:
approx. 200 bar (battery fully charged)
Steering
pressure OK?
yes
no Perform trouble shooting
for front steering system
Check the rear steering pres-
sure
- Connect a 600 bar pressure
gauge to the steering pressure
test port
- Enter code number 600
- Pull the plug off the starter so-
lenoid and crank the engine
with the starter
- Turn the rear steering against
one of the end stops and readthe pressure gauge
Nominal value:
approx. 200 bar (battery fully
charged)
Steering
pressure OK?
yes
no Perform trouble shooting
for rear steering system
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Check leakage
of brake
- Release the brake and perform acharge pressure test
Charge pressure
OK?
no
yes
- Disconnect the brake releasing
lines one after the other from thedrum drive motors and close them
with plugs; repeat the charge pres-
sure test with the brake closed
- Repair the unit with which the
charge pressure is OK after thebrake line has been disconnected
Valve OK?
yes
no Replace the charge pres-
sure relief valve
Check the charge pres-
sure relief valve
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Flushing valve
OK?
noyes Replace the flushing valve
Check the flushing valve
Check the travel pump
- Close the high pressure ports on the
pump with plugs
- Repeat the pressure test
High pressure
OK?
no
Check the control chamber pres-
sure
- Install pressure test ports with 60
bar pressure gauges to X3/X4
Pressure OK?
no
yes
yes
- Actuate the travel pump to fulldisplacement and read the pres-
sure gauge
Nominal value: approx. 15 bar
Replace/repair
the travel pump
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Nozzles OK?no
yes
Check the swash time nozzles
- Unscrew the nozzles and check
for blockage
Clean the nozzles
Check the case pressure
- Install a pressure test port witha 10 bar pressure gauge to G
Pressure OK?no
yesCheck the leak oil return
line to the tank
- Actuate the travel pump to full dis-
placement and read the pressuregauge
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Test the travel motors individually
- Close the high pressure test ports on
the drum drive motors one after the
other with plugs
- Repeat the pressure test
- If the high pressure is O.K., replace
the travel motor excluded from the
hydraulic circuit.
Replace/repair
the travel pump
Servo control
OK?
no
Repair the servo
control
Check the servo control
- Remove the servo control
- Check the nozzles, clean if nec-
essary.
- Check the linkage, repair if nec-
essary
yes
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Hydraulic oil overheating >90 °C
Valves
OK?
yes
no
Check the high pressure relief valves in
the travel circuit
- Enter code number 500 to close the
brake
- Fully actuate the travel lever
- Check the high pressure relief valves for
excessive heat
Check high pressure relief valves in vi-
bration circuit
- Stand the drums on rubber tires
- Switch the vibration on
- Check high pressure relief valves for ex-
cessive heat
Check the high pressure
relief valves/pressure override
Check the thermostat valve
- Check whether the hose to the cool-
er heats up when a hydraulic oil
temperature of > 60 °C is reached
Thermostat
OK?
yes
no Replace the thermostat
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Check the flushing valve in the travel sys-
tem
- Check the moveability of the flushing valve
Check the flushing valve in the vibration
system
- Check the moveability of the flushing valve
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No vibration at front and rear
Travel system O.K.
Current
OK?
yes
no Perform trouble shooting
in the electric system
Check the control chamber pressure
- Install pressure test ports to X1 and X2
- Connect a 60 bar pressure gauge
- Run the engine with maximum speed
- Switch the vibration on and read the pres-
sure gauge
Nominal value: approx. 12 bar
Pressure
OK?
yes
no
Check the electric power supply for the
solenoid valves
- Switch the vibration on and measure the
current consumption of both solenoids
Nominal value: approx. 1.7 A
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Check the vibration pump
- Connect 600 bar pressure gauges to the vi-
bration pump- Close high pressure ports A and B with plugs
- Run the engine with maximum speed .
- Switch the vibration on for a moment and read
the pressure gauge
Nominal value: approx. 380 bar
Check the control unit
- Remove the control unit
- Check the nozzle, clean if neces-sary.
- Check the control piston, if nec-
essary replace the control unit
Pressure
OK?
yes
no Replace/repair
the vibration pump
yes
no Replace / repair
the coupling
Replace/repair
the vibration motor
Check the vibrator shaft bearings
- Remove the vibration motor
- Check end float and moveability
of the vibrator shafts
- Check the coupling
Bearing /
coupling
OK?
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Speed of front and rear vibrator shafts too low
Rated speed
OK?
yes
no Perform engine
trouble shooting
Checking the engine speed
- Switch vibration on and measure the speed
Nominal value:
Nominal speed 2600 rpm
yes
no
- Adjust high
and low fre-
quency
yes
no
Check the pressures in the vibration circuit
- Connect 600 bar pressure gauges to the high pressure test
port
- Connect a 60 bar pressure gauge to the charge pressure
test port
- Run the engine with maximum speed.
- Switch the vibration on and read the pressure gauge
Nominal value:
Start up pressure: 380 ±20 bar
Operating pressure: approx. 100 bar (depending on soil)
Charge pressure: approx. 26 bar
Charge
pressure OK?
Drop in vibrator
shaft speed
>10%
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no, to high
yesOperating
pressure OK?
no
yesStart-up
pressure OK?
Check the leak oil rateof both vibration mo-
tors
- Measure the leak oil
rate at a vibration
measure of approx.
100 bar
Nominal value:max. 1 l/min
yes
noLeak oil OK? Replace the respective vi-bration motor
Check the vibrator shaft bearings
- Check end float and moveability of the vibra-
tor shafts
End float:
1,0 ... 3.3 mm
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Check the vibration pump
- Close high pressure ports A and B with plugs
- Switch the vibration on for a moment and
read the pressure gauges
Nominal value:
380 ±20 bar
Pressure OK?
yes
no
Test the individual vibration
motors
- Close the high pressure hoses
of the individual vibration mo-
tors one after the other with
plugs and repeat the pressure
test
- If the high pressure is O.K., re-
place the travel motor excluded
from the hydraulic circuit.
Pressure OK?yes
no
Check the control cham-ber pressure
- Install pressure test ports
with 60 bar pressure
gauges to X1and X2
- Switch the vibration on
and read the pressure
gauge
Nominal value:
approx. 15 bar
Replace/repair
the vibration pump
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Replace/repairthe travel pump
Servo control
OK?
no Replace the servo
control
Check the servo control
- Remove the servo control
- Check the nozzles, clean if
necessary.
yes
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No front steering steering sticky
Steering
pressure OK?
yes
no
Check the front steering pressure
- Connect a 600 bar pressure gauge to the
steering pressure test port
- Enter code number 600
- Pull the plug off the starter solenoid and
crank the engine with the starter
- Turn the front steering against one of the
end stops and read the pressure gauge
Nominal value:
approx. 200 bar (battery fully charged)
Check the front steering pump
- Close the pump outlet with a 200bar pressure relief valve
- Connect a 600 bar pressure
gauge
- Crank the engine with the starter
- Read the pressure gauges
Nominal value:
approx. 200 bar (battery fullycharged)
Pressure OK?
yes
no
Change the steering /
charge pump
Check / replace thefront steering cylinder
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yes
noSteering
pressure OK?Replace the steering valve
Check the front steering valve- Install a 600 bar pressure gauge to the
steering pressure outlet
- Enter code number 600
- Turn the front steering against an end stop
Nominal value:
approx. 200 bar
Check the moveability
of steering cylinders
and pivot bearing
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No rear steering steering sticky
Steering
pressure OK?
yes
no
Check the rear steering pressure
- Connect a 600 bar pressure gauge to the
steering pressure test port
- Enter code number 600
- Pull the plug off the starter solenoid and
crank the engine with the starter
- Turn the rear steering against one of the
end stops and read the pressure gauge
Nominal value:
approx. 200 bar (battery fully charged)
Check the rear steering pump
- Close the pump outlet with a 200
bar pressure relief valve
- Connect a 600 bar pressure
gauge
- Crank the engine with the starter
- Read the pressure gauges
Nominal value:
approx. 200 bar (battery fully
charged)
Pressure OK?
yes
no
Change the steering /
charge pump
Check / replace therear steering cylinder
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yes
noSteering
pressure OK?Replace the steering valve
Check the rear steering valve- Install a 600 bar pressure gauge to the
steering pressure outlet
- Enter code number 600
- Turn the rear steering against an end stop
Nominal value:
approx. 200 bar
Check the moveability
of steering cylinders
and pivot bearing
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5 Drum
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5.1 Special tools
1. Lifting device for vibrator unit
BOMAG part-no. 007 215 08
2. Screw bolt for vibrator unit lifting device
Fig. 1
Fig. 2
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Fig. 1 Drum
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1 Vibrator housing
2 Vibrator shaft
3 Drum drive motor
4 Rubber buffer
5 Vibrator shaft coupling
6 Change-over weight
7 Vibrator shaft bearing
8 Travel bearings
9 Vibration motor
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5.3 Removing and installing the drum
Note
Removal and installation of the drum is exempla- ry described for the front drum. The rear drum
must be removed and installed in the same way.
Removal
1. Drain the water from the corresponding watertank for the water sprinkling system.
2. Fasten lifting gear to front and rear frame (Fig. 1).
3. Lift the machine up, until the rubber buffers areunloaded.
4. Remove the cover plates (Fig. 2) from both sides.
5. Disconnect water hoses 1 (Fig. 3) from the sprin-kling tubes.
6. Remove scraper brackets (2) with the sprinklingtubes .
Fig. 1
Fig. 2
Fig. 3
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7. Mark the hydraulic hoses (Fig. 4) on the vibrationmotor and disconnect them from the ports.
Caution
Close all openings with plugs.
Environment
Catch running out oil and dispose of environ-mentally.
8. Mark the hydraulic hoses on the travel motor (Fig.5) and disconnect them from the ports.
CautionClose all openings with plugs.
Environment
Catch running out oil and dispose of environ-mentally.
9. Open the hose brackets (Fig. 6) on both sides of
the support legs and pull the hoses out of thesuport legs.
10. Unscrew fastening screws (Fig. 7) from the sup-port legs.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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Danger
Danger of squashing!
Do not step under suspended loads.
11. Fasten lifting gear to the support leg and unscrewfastening screws (Fig. 8).
12. Pull the support leg off and lay it down.
13. Remove the support leg also from the oppositeside.
14. Lift the machine up (Fig. 9), so that the drum canbe removed from under the frame.
15. Support the frame safely.
16. Check rubber buffers (Fig. 10), replace if neces-
sary.
Fig. 8
Fig. 9
Fig. 10
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Installation
Danger
Danger of squashing!
Do not step under suspended loads.
1. Lift up the frame and roll the drum parallel underthe frame (Fig. 11).
2. Assemble the support legs to the drum (Fig. 12).
3. Tighten all fastening screws for both support legs
and remove the lifting gear.
4. Align the bores in the support leg with the boresin the traverse, turn in and tighten the fasteningscrews (Fig. 13).
5. Connect the hydraulic hoses for the travel motor(Fig. 14) by following the marking and tightenthem.
Fig. 11 872739
Fig. 12 872740
Fig. 13 872741
Fig. 14 872734
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6. Connect the hydraulic hoses for the travel motor(Fig. 15) by following the marking and tightenthem.
7. Fasten the hose bracket (Fig. 16) to the supportlegs on both sides.
8. Fasten the cover plates (Fig. 17) on both sides.
9. Install scrapers and water sprinkling tubes (Fig.18).
Fig. 15 872733
Fig. 16 872732
Fig. 17 872730
Fig. 18 732731
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5.4 Removing and installing the vibratorunit on the drum drive side
1. Remove the drum.
Environment
Catch running out oil and dispose of environ-mentally.
2. Drain the oil from the drum.
Removing the vibrator unit
1. Unscrew the fastening nuts (Fig. 1) and take offthe angle plate.
2. Examine all rubber buffers 1 (Fig. 2) for wear, re-place if necessary.
3. Unscrew the fastening screws (Fig. 3) and take
off the drive disc with rubber buffers.
Fig. 1
Fig. 2
Fig. 3
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4. Unscrew two fastening screws opposite each oth-er (Fig. 4) and turn in guide bolts.
5. Unscrew all other fastening screws.
6. Turn adapter 1 (Fig. 5) of the lifting device withthree washers (2) into the travel motor.
DangerDanger of squashing!
Do not step under suspended loads.
7. Fasten the lifting device to a crane and slide itover the adapter.
8. Pull the travel motor off the flange.
Caution
If dirt or chips are found in the travel motorflush the hydraulic system before restarting
the machine. 9. If necessary unscrew the fastening screws (Fig.
6) and take off the flange.
Fig. 4
Fig. 5
Fig. 6
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10. Unscrew two fastening screws opposite each oth-er (Fig. 7) and turn in guide bolts.
11. Unscrew all other fastening screws and force thehousing off with the help of two screws.
12. Fasten the lifting device to the flange and pull thehousing out of the drum (Fig. 8).
13. Take off the O-ring.
Installing the vibrator unit
Caution
Fitting and contact surface of the connectionbetween vibration unit and drum must be ab-solutely dry and free of grease, oil, paint andconserving agent.
Note
Always assemble the vibration unit on the drumdrive side first.
1. Grease and assemble the O-ring (Fig. 9).
2. Fasten the lifting device to the flange and turn twoguide bolts into the drum(Fig. 10).
3. Insert the vibrator unit into the drum.
Fig. 7
Fig. 8
Fig. 9
Fig. 10
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4. Remove the guide bolts (Fig. 11).
5. Turn in and tighten the fastening screws.
6. Attach the flange to the drum drive motor, turn inand tighten the fastening screws (Fig. 12).
7. Turn adapter 1 (Fig. 13) of the lifting device with
three washers (2) into the travel motor.
Danger
Danger of squashing!
Do not step under suspended loads.
8. Fasten the lifting device to a crane and slide itover the adapter.
Caution
If dirt or chips are found in the travel motor
flush the hydraulic system before restartingthe machine.
9. Turn in two guide bolts.
10. Push on the drum drive motor, turn in and tightenthe fastening screws (Fig. 14).
Fig. 11
Fig. 12
Fig. 13
Fig. 14
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11. Attach the drive disc with rubber buffers, turn inand tighten the fastening screws (Fig. 15).
12. Attach the angle plate, turn on and tighten thefastening nuts with washers (Fig. 16).
Fig. 15
Fig. 16
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5.5 Removing and installing the vibratorunit on the vibration drive side
1. Remove the drum.
Environment
Catch running out oil and dispose of environ-mentally.
2. Drain the oil from the drum.
3. Remove the vibrator unit on the drum drive side.
Removing the vibrator unit
1. Unscrew the fastening nuts (Fig. 1) and take offthe angle plate.
2. Examine all rubber buffers (Fig. 2) for wear, re-place if necessary.
3. Unscrew fastening screws 1 (Fig. 3) and take offthe vibration motor (2).
Caution
If dirt or chips are found in the travel motorflush the hydraulic system before restartingthe machine.
Fig. 1
Fig. 2
Fig. 3
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4. If necessary unscrew fastening screw 1 (Fig. 4)and pull off coupling hub (2).
5. Remove coupling element 1 (Fig. 5)and pull offcoupling hub (2).
6. Unscrew the fastening screws (Fig. 6) and re-
move the cover.
7. Unscrew the fastening screws (Fig. 7) and takeoff the intermediate ring.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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8. Take off the V-ring (Fig. 8).
9. Remove the circlip (Fig. 9).
10. Attach the lifting gear side plate (Fig. 10).
Danger
Danger of squashing!
Do not step under suspended loads.
11. Pull the side plate off the flange using a specialpulling device (Fig. 11).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
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12. Press the travel bearing (Fig. 12) out, check itscondition and replace if necessary.
13. Take off the V-ring (Fig. 13).
14. Unscrew the fastening screws (Fig. 14) and take
off the flange.
15. Turn two guide bolts into the drum and unscrewthe fastening screws (Fig. 15).
Fig. 12
Fig. 13
Fig. 14
Fig. 15
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16. Fasten the lifting device to the flange and pull thehousing out of the drum (Fig. 16).
17. Take off the O-ring.
18. Remove circlip 3 (Fig. 17) from coupling sleeve(1).
19. Pull off coupling and disc (2).
Installing the vibrator unit
Caution
Fitting and contact surface of the connectionbetween vibration unit and drum must be ab-solutely dry and free of grease, oil, paint andconserving agent.
Note
Always assemble the vibration unit on the drumdrive side first.
1. Grease and assemble the O-ring (Fig. 18).
2. Push on coupling sleeve 1 (Fig. 19).
3. Insert disc (2) and assemble circlip (3).
Fig. 16
Fig. 17
Fig. 18
Fig. 19
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4. Turn two guide bolts into the drum (Fig. 20).
5. Attach the lifting gear to the flange and insert thehousing carefully into the drum.
Caution
Ensure correct engagement of the coupling!
After installation the vibrator shaft must stillhave sufficient end float.
6. Unscrew the guide bolts, turn in and tighten thefastening screws (Fig. 21).
7. Attach the flange, turn in and tighten the fastening
screws (Fig. 22).
8. Press the travel bearing with spacer disc (Fig. 23)into the drive disc.
Fig. 20
Fig. 21
Fig. 22
Fig. 23
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9. Assemble the V-ring . (Fig. 24)
10. Attach the lifting gear to the side plate and placeit onto the flange (Fig. 25).
DangerDanger of squashing!
Do not step under suspended loads.
11. Pull the side plate onto the flange using a special
pulling device (Fig. 26).
12. Insert the circlip into the groove (Fig. 27).
Fig. 24
Fig. 25
Fig. 26
Fig. 27
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13. Assemble the V-ring (Fig. 28).
14. Assemble the intermediate ring, turn in and tight-en the fastening screws (Fig. 29).
15. Attach the cover, turn in and tighten the fastening
screws (Fig. 30).
16. Pull the vibrator shaft towards you (Fig. 31) (musttouch the collar of the bearing on the drive side).
Fig. 28
Fig. 29
Fig. 30
Fig. 31
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17. On the vibration drive side of the drum measurethe depth to the stop of the coupling hub on thevibrator shaft (Fig. 32).
Nominal value:
122 ... 121.8 mm
18. Compensate the difference to the measured val-ue with shims between coupling hub and vibratorshaft.
19. Insert shims (Fig. 33) of calculated thickness.
Note
If the fitting key is already assembled the shimsmust be punched out accordingly.
20. Press the coupling have 2 (Fig. 34) onto the vibra-
tor shaft and insert coupling element (1).
Caution
Mind the fitting key!
21. Slide coupling hub 2 (Fig. 35) onto the shaft andtighten fastening screw (1).
Fig. 32
Fig. 33
Fig. 34
Fig. 35
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22. Install the vibration motor 2 (Fig. 36), turn in andtighten the fastening screws (1).
23. Assemble the angle plate, turn on and tighten thefastening nuts (Fig. 37).
24. Fill in oil as specified in the maintenance instruc-
tions.
Fig. 36
Fig. 37
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7. Take the vibrator unit (Fig. 4) out of the housing.
8. Check the condition of the inner bearing race(Fig. 5), replace if necessary.
9. Pull coupling pinion 1 (Fig. 6) off the exciter shaft.
10. Check the condition of the inner bearing race (2),pull off if necessary.
11. Remove circlip 1 (Fig. 7).
12. Press bearing (2) out of the housing.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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Assembling the vibrator unit
1. Press bearing 2 (Fig. 8) into the housing.
2. Assemble circlip (1).
Danger
Danger of burning!
Wear protective gloves.
3. Heat the inner bearing race up to approx. 80 °C.
4. Push inner bearing race 3 (Fig. 9) with the collartowards the eccentric weight all the way againstthe end stop.
5. Insert circlip (2) into the groove in the vibratorshaft.
6. Insert the fitting key into the keyway in the vibratorshaft.
7. Heat coupling pinion (1) up to approx. 80 °C and
slide it onto the shaft against the stop.
Danger
Danger of burning!
Wear protective gloves.
8. Heat the inner bearing race up to approx. 80 °C.
9. Push inner bearing race 2 (Fig. 10) with the collartowards the eccentric weight all the way againstthe end stop.
10. Insert circlip (1) into the groove in the vibrator
shaft.
Fig. 8
Fig. 9
Fig. 10
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16. Attach the flange to the housing (Fig. 15).
17. Insert and tighten fastening screws 1 (Fig. 16).
18. Insert the plugs into the forcing off bores (2) withseal rings.
19. Check the end float of the vibrator shaft (Fig. 17).
Nominal value:
0.6 ... 1.2 mm
Fig. 15
Fig. 16
Fig. 17
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5.7 Repairing the vibrator unit on the vi-bration drive unit
1. Remove the vibrator unit.
Dismantling the vibrator unit
1. Unscrew the fastening screws (Fig. 1) and takethe flange off the housing.
2. Take the flange off the housing (Fig. 2).
3. Take off the O-rings.
4. Pull radial seal 1 (Fig. 3) out of the flange.
5. Unscrew plugs (2).
Note
The bores with the plugs (2) are used to force offthe cylinder roller bearings.
Fig. 1
Fig. 2
Fig. 3
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6. Remove circlip 1 (Fig. 4).
7. Force bearing (2) out of the flange with the helpof screws.
8. Take the vibrator unit (Fig. 5) out of the housing.
9. Check the condition of inner ring 1 (Fig. 6) for ra-
dial seal and inner bearing race (2), pull off if nec-essary.
10. Pull coupling pinion 1 (Fig. 7) off the exciter shaft.
11. Check the condition of the inner bearing race (2),pull off if necessary.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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12. Remove circlip 1 (Fig. 8).
13. Press bearing (2) out of the housing.
Assembling the vibrator unit
1. Press bearing 2 (Fig. 9) into the housing.
2. Assemble circlip (1).
Danger
Danger of burning!
Wear protective gloves.
3. Heat the inner bearing race up to approx. 80 °C.
4. Push inner bearing race 6 (Fig. 10) with the collartowards the eccentric weight all the way againstthe end stop.
5. Insert circlip (5) into the groove in the vibratorshaft.
6. Insert fitting key (4) into the keyway in the vibrator
shaft.
7. Slide locking ring (3) and washer (2) to fasten thecoupling onto the shaft.
8. Heat coupling pinion (1) up to approx. 80 °C andslide it onto the shaft against the stop.
Fig. 8
Fig. 9
Fig. 10
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Danger
Danger of burning!
Wear protective gloves.
9. Heat the inner ring and inner bearing race up toapprox. 80 °C.
10. Push inner bearing race 3 (Fig. 11) with the collartowards the eccentric weight all the way againstthe end stop.
11. Insert circlip (2) into the groove in the vibratorshaft.
12. Slide inner ring (1) with the chamfered side to-wards the outside onto the shaft.
13. Move the vibrator unit (Fig. 12) carefully into thehousing, until the inner bearing race is seated inthe bearing.
14. Press bearing 2 (Fig. 13) into the housing.
15. Assemble circlip (1).
16. Grease the O-ring and lay it into the groove (Fig.14).
Fig. 11
Fig. 12
Fig. 13
Fig. 14
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17. Grease the O-ring and lay it around the collar(Fig. 15).
18. Attach the flange to the housing (Fig. 16).
19. Turn in and tighten the fastening screws (Fig. 17).
20. Press the new radial seal 1 (Fig. 18) into thehousing with the sealing lip pointing down.
21. Insert the plugs into the forcing off bores (2) withseal rings.
Fig. 15
Fig. 16
Fig. 17
Fig. 18
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22. Check the end float of the vibrator shaft (Fig. 19).
Nominal value:
0,6 ... 1.2 mm
Fig. 19
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9. Attach the cover (Fig. 8) to the housing.
10. Cover the fastening screws with LOCTITE green(No. 601).
11. Tighten the fastening screws evenly with 35 Nm.
Fig. 8
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6 Pivot steering
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6.1 Removing, repairing and installing thepivot steering
Removal
1. Remove the respective drum (see respective
section). 2. Disconnect the steering cylinders (Fig. 1) on both
sides from the cross-member.
3. Unscrew all fastening screws from the hood (Fig.2) and take off the hood.
4. Remove steering angle transducer 1 (Fig. 3) andcover (2).
Fig. 1
Fig. 2
Fig. 3
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5. Pull hydraulic hoses and electric cables (Fig. 4)out of the cross member.
6. Attach the lifting tackle to the cross-member (Fig.5).
DangerDanger of squashing!
Do not step under suspended loads.
7. Unscrew all fastening screws (Fig. 6) from both
sides and lower the cross-member to the ground.
8. Unscrew all fastening screws (Fig. 7) and lowerthe transom bed to the ground.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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9. Check four point bearing , replace if necessary.
Danger
Danger of squashing!
Support the bearing so that it cannot fall
down.
10. Unscrew all fastening screws (Fig. 8) from thefour-point bearing and take the bearing off.
Installation
Danger
Danger of squashing!
Do not step under suspended loads.
1. Lift up the cross-member and place it in front ofthe transom bed (Fig. 9).
2. Turn in and tighten the fastening screws (Fig. 10).
3. Route hydraulic hoses (Fig. 11) and electric ca-bles through the cross member.
Fig. 8
Fig. 9
Fig. 10
Fig. 11
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4. Assemble the steering angle transducer (Fig. 12)with the angle plate.
Caution
Adjust the angle transducers before starting
operation of the machine!
5. Connect the steering cylinders (Fig. 13) with thecross-member.
6. Reinstall the drum (see corresponding section).
7. Calibrate and adjust the steering angle transduc-ers (see respective section).
8. Reassemble the hood (Fig. 14) and perform atest drive.
Fig. 12
Fig. 13
Fig. 14
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6.2 Repairing the oscillation joint
Dismantling the oscillation joint
1. Remove drum and pivot steering (see corre-sponding section).
2. Unscrew the fastening screws (Fig. 1) and re-move the cover.
3. Pull out the rocker bearing (Fig. 2) and take offthe supporting disc.
4. Remove the cover (Fig. 3) also on the other sideand pull out the rocker bearing.
Fig. 1
Fig. 2
Fig. 3
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5. Press the joint bolt out using three screws (Fig.4).
6. Lift the beam out of the cross member (Fig. 5).
Assembling the oscillation joint
1. Insert the beam into the cross member and knockin the joint bolt (Fig. 6).
2. Insert the support ring and press the joint ring(Fig. 7) onto the joint bolt.
3. Spray the joint ring with sliding agent OKS 571(BOMAG part-no. 009 700 26).
Caution
Insert the rocker bearing without grease, useonly sliding agent OKS 571 (BOMAG part-no.009 700 26).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
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7 Suppliers documentation
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Reparaturanleitung A4VG
Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 3
Schnittbild
Sectional view
HWD
EPD
DAD
HDD
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Reparaturanleitung A4VG
Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 5
Turcon-Glyd-Ring Dichtung
Turcon-Glyd-ring seal
Deckel Stelldruck
Stellzylinder
Lecköl
Führungsbuchse
Turcon-Glyd-Ring
Pumpengehäuse
Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstel-lung der Verstellung auf Turcon-Dichtungen.Die Stückliste der kompletten Einheit erhält dabei eineneue Ident.- Nummer.Typenschlüssel, Typnummer und Außenabmeßungenbleiben dabei unverändert. (Pumpengehäuse ändert sichnur im Bereich vom Stellkolben. Stellkolben ändert sich ineine angefaste Ausführung).
Alten Stellkolben nicht bei Turcon-Dichtung ver-wenden (scharfkantig - Dichtungen werdenbeschädigt).
Pumpengehäuse / Pump housingmit Lagerbuchse / with bush ALT / OLD
At present the change of the control into Turcon seal ismade for A4VG.The parts list of the complete unit will receive a newidentification number.Type reference and outside dimensions remainunchanged (pump housing will change at the area of thepositioning piston. Positioning piston will change intochamfering design).
Do not use old positioning piston with Turcon seal(sharp edged - seal will be damaged)
Pumpengehäuse / Pump housingmit Turcon-Dichtung / with Turcon seal NEU / NEW
Die Umstellung der Verstellung auf Turcon-Dichtung ist im allgemeinen mit einer Funktions-verbesserung verbunden (DA-Verhalten, geringererTemperatureinfluß auf Stellzeiten).
Bei gleicher Düsenbestückung können sich dieStellzeiten geringfügig verändern.
The change of the control into Turcon seal designimproves in general the function (DA-behaviour,lower temperature-influence on control times).
The control times will slightly change with thesame throttle sections. Therefore our customershave to be informed about this change.
* *
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Repair Instructions A4VG
RDE 92003-01-R/05.99
6 Brueninghaus Hydromatik
Achtung!Nachfolgend Hinweise bei allen Reparaturarbeitenan Hydraulikaggregaten beachten!
Attention!Observe the following notices when carrying out repairwork at hydraulic aggregates!
Alle Öffnungen der Hydraulikaggregate verschließen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.Nur original BRUENINGHAUS HYDROMATIK-Ersatzteileverwenden.
Replace all seals.Use only original BRUENINGHAUS HYDROMATIKspare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.Achtung: Nacharbeiten an Dichtflächen z.B. durchSchleifpapier kann die Oberfläche beschädigen.
Check all seal and sliding surfaces for wear.Attention: Rework of sealing area f. ex. with abrasivepaper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mitBetriebsmedium befüllen.
Fill up hydraulic aggregates with mediumbefore start- up.
Allgemeine Reparaturhinweise
General repair instructions
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 7
Dichtsätze und Baugruppen
Seal kits and sub assembly groups
1 Dichtsatz für Triebwelle.
Seal kit for drive shaft.
3 Gehäuse
Housing
2 Äußerer Dichtsatz.
External seal kit.
4 Triebwerk komplett.
Complete rotary group.
5 Stellkolben
Positioning piston
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Repair Instructions A4VG
RDE 92003-01-R/05.99
8 Brueninghaus Hydromatik
Baugruppen
Sub assemblies
6 Anschlußplatte
Port block
8 Ansteuergeräte HD - DA
Control moduls HD - DA
7 Ansteuergeräte HW - EP
Control moduls HW - EP
9 Hilfspumpe
Boost pump
10 Regelventil
Control valve
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Reparaturanleitung A4VG
Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 9
Triebwelle abdichten
Sealing of the drive shaft
13 Blechschraube in die mit Gummi gefülltenLöcher eindrehen.Mit Zange WDR herausziehen.
Screw in sheet metal screw into the holesfitted with rubber.Pull out shaft seal with pliers.
14 Wellendichtring mit Buchse aufAnschlag einpressen.
Press-in shaft seal with bush to stop.
12 Triebwelle abkleben.Sicherungsring ausbauen.
Protecting the drive shaft.Remove retaining ring.
11
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Reparaturanleitung A4VG
Repair Instructions A4VG
RDE 92003-01-R/05.99
12 Brueninghaus Hydromatik
Stellkolbendeckel abdichten
Sealing of the control piston cover
23 Über 0-Lagen-Einstellschraube Deckel abdrückenund drehen.
Pull cover off using zero position adjustment screw.
25 Gewinde abdecken, kleinen O-Ring aufschieben.Montage in umgekehrter Reihenfolge.
Cover threads, push on small O-ring.Assemble in reversed order.
24 Kontrolle!O-Ring (1), Nut (2), Gehäuse (3).
Check!O-ring (19, groove (2), housing (3).
26 Achtung!Korrekte mechanische Nullageneinstellung muß nachEinbau im Gerät bzw. Prüfstand erfolgen.
Attention!Adjustment of the correct zero position to be carried out
after installation into the machine or on the test bench.
27 Mechanische Nullage neu einstellen, dazu X1 mit X
2
verbinden (>NW6).
Reset mechanical zero position. To do this, connectX
1 to X
2 (size > 6).
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RDE 92003-01-R/05.99
Brueninghaus Hydromatik 13
Ventile abdichten
Sealing of the valves
29 Gewinde vor Montage des neuen O-Ringes abkleben.(Beschädigungsschutz).
Cover threads before fitting new O-rings.(Damage protection).
30 Ventilkegel mit Druckfeder ausbauen.* mit Bypassfunktion
Remove valve poppet with spring.* with bypass-function
31 Gewinde vor Montage des neuen O-Ringes abkleben.(Beschädigungsschutz).
Cover threads before fitting new O-rings.(Damage protection).
PSP
-Ventil
PSP
-valve
*
PHD
-Ventil mit Bypass
PHD
-valve with bypass-function
28
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Repair Instructions A4VG
RDE 92003-01-R/05.99
14 Brueninghaus Hydromatik
Druckabschneidung abdichten
Sealing of the pressure cut-off valve
31
33 Wechsel der Dichtmutter.Einstellmaß festhalten (*).
Change of the sealing nut.Note setting measure (*).
Achtung!Nach Einbau "Ventileinstellung" überprüfen.
Attention!After assembly check "valve setting".
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 15
Regelventil abdichten
Sealing of the control valve
36 Blendendurchmesser nicht beschädigen.
Do not damage throttle diameter.
37 Gewinde vor Montage des neuen O-Ringes abkleben.
Before installing the new O-ring, tape the threads.
35 Regelventil ausbauen.
Remove control valve.
34
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Repair Instructions A4VG
RDE 92003-01-R/05.99
16 Brueninghaus Hydromatik
Steuergerät demontieren
Removing of the control module
40 Ansteuergerät abdrücken.
Pry-off the control module.
41 KontrolleDichtfläche (1), Flachdichtung (2), O-Ringe (3).
CheckSealing surface (1), gasket (2), o-rings (3).
39 Befestigungsschrauben demontieren.
Remove fixing screws.
38
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 17
Ansteuergeräte
Control modules
44 Hydraulische Nullage (1) neu einstellen. BeideManometer müssen gleichen Druckwert anzeigen.
Reset hydraulic zero position (1).Both gauges must indicate the same pressure.
Ansteuergerät HW
HW control module
42
Ansteuergerät HD - EP
HD - EP control module
43
HD
HD
EP
EP
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Repair Instructions A4VG
RDE 92003-01-R/05.99
18 Brueninghaus Hydromatik
Pumpe demontieren
Pump disassembly
46 Lage der Hilfspumpe und Anschlußplatte markieren.Hilfspumpe abbauen.
Mark position of the boost pump and the port plate.Remove the boost pump.
45
47 Lage der Verdrillschraube markieren (1).Verdrillschraube auf Demontageposition stellen (2).
Mark the position of the indexing screw (1).Set the indexing screw to disassembly position (2).
48 Anschlußplattenbefestigung lösen. Anschlußplatte abheben.Achtung! Dichtfläche.
Release port plate fitting.Take off port plate. If necessary, use screwdriver.Attention! Sealing surface.
Verschlußschraube / Stift
Locking screw / pin
VerdrillschraubeTiming adjustment screw
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 19
Pumpe demontieren
Pump disassembly
49 Steuerplatte abdrücken.Lage notieren.
Lift off control plate.
Note position.
51 Zylinder nach unten drücken (1).Verdrillschraube herausdrehen (2).Triebwerk ausheben (3).
Press the cylinder to the bottom (1).Remove fiming indexing screw (2).Lift out rotary group (3).
50 Kontrolle!O-Ring mit Nut (1), Gehäuse (2), Quad-Ring undQuad-Ring Nut (3).
Check!
O-ring and groove (1), housing (2), Quad-ringand groove (3).
"Ausbauen"1. Zylinder2. Schwenkwiege3. Gelenkstift
"Remove"1. Cylinder
2. Swash plate3. Joint pin
52
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Repair Instructions A4VG
RDE 92003-01-R/05.99
20 Brueninghaus Hydromatik
Triebwerk ausbauen
Removal of the rotary group
56
53 Seegerring, WDR ausbauen.
Remove retaining ring, radial seal ring.
54 Triebwelle mit leichten Hammerschlägen austreiben.
Remove drive shaft with slight hammer strokes.
55 Lagerschalen ausbauen.
Remove bearing cups.
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 21
60 Vorrichtung aufsetzen und Feder vorspannen.Aufnahmering ausbauen.
Mount fixture and tension spring.Remove receiving ring.
Stellkolben demontieren
Disassembly of the positioning piston
57
61 Ringe ausbauen.Sicherungsring ausbauen.Achtung! Teile stehen unter Federvorspannung.
Take out rings.Remove retaining ring.Note! Parts are spring loaded.
59 Stellkolben (1) ziehen.
Pull out control piston (1).
58 Steuergerät abbauen.
Remove control module.
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Repair Instructions A4VG
RDE 92003-01-R/05.99
22 Brueninghaus Hydromatik
Überprüfungshinweise
Inspection notes
62 Alle Lager erneuern.
Replace all bearings.
64 Stellkolbenlaufbüchse (1) riefenfrei, nicht ausgelaufen.
Check that the control piston guide bush (1) isfree of grooves and has not worn out.
63 Kontrolle!1. Verzahnung, ausgeschlagen, Passungsrost.2. Lauffläche.3. Einlaufrillen vom Wellendichtring.
Check!1. Splines for damage or fretting.2. Running surfaces.3. Groove cut by shaft seal.
65 Kontrolle!Stellkolben (1) riefenfrei.
Check!Control piston (1) is not scored.
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 23
Kontrolle der Triebwerksteile
Inspection of rotary group parts
66 Kontrolle!Gleitfläche riefenfrei.
Check!
Sliding surface free of grooves.
68 Kontrolle!Rückzugeinrichtung riefenfrei (1), keine Einlaufspuren (2)im Gleitschuhbereich.
Check!Check that return device is free of grooves (1) no wearin slipper pad area.
67 Kontrolle!Verbindung Gleitstein/Schwenkzapfen spielfrei.
Check!Make sure sliding ring/swivel pin are free of play.
69 Kontrolle!Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!Check that there are no scratches or metal deposits onsliding surface (1), and there is no axial play (2),(otherwise: pistons must be replaced in sets).
70 Kontrolle!Zylinderbohrungen (1), Verzahnungen (2).
Check!Cylinder bores (1), splines (2).
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Repair Instructions A4VG
RDE 92003-01-R/05.99
24 Brueninghaus Hydromatik
Kontrolle der Triebwerksteile
Inspection of rotary group parts
71 Kontrolle!Zylindergleitfläche (1) riefenfrei, nicht eingelaufen, keineEinlagerungen, Steuerplatte (2) nicht riefig (nur satzweiseaustauschen).
Check!Cylinder gilding surface (1) free of scratches, no traces ofwear and no embedded foreign particles. No scratcheson the valve plate (2). (Replace ONLY in sets).
73 Hinweis:Bohrung bei DA-Regelung offen. OhneDA-Regelventil geschlossen.
Information:Boring for DA-control open.Without DA-control closed.
72 Kontrolle!DU-Lagerbuchse (1) nicht ausgelaufen.
Check!DU-bearing bush (1) is not worn out.
74 Kontrolle!Lagerbahnen (1)
Check!Bearing surfaces (1)
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Repair Instructions A4VG
RDE 92003-01-R/05.99
Brueninghaus Hydromatik 25
Stellkolben, Triebwerk einbauen
Positioning piston, rotary group assembly
Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring
82
Pos. / Item 1: Stangenführungsring montieren.
Install barguide ring.
Pos. / Item 3: O-Ring montieren.
Install O-ring.
2
3
3
2
1
1
Montage / Assembly A4VG
Pos. / Item 1
Pos. / Item 2 / 3
Pos. / Item 2 / 3
Pos. / Item 1
Hilfswerkzeuge / Auxiliary tools:
Montagezange / Assembly pliers: B+S x M22 Führungsdorn / Guide thorn: A4VG28 I: 277 4 347A4VG40 I: 277 4 049A4VG56 I: 277 4 050A4VG71 I: 277 4 051A4VG90 I: 277 4 052A4VG125 I: 277 4 053A4VG180 I: 277 4 054A4VG250 I: 277 4 072
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26 Brueninghaus Hydromatik
Dichtring (Pos. 2) in die Montagezange einlegen.
Fit the seal ring (Item 2) into the assembly tool.
Führungsdorn in Stellkolben einbauen.
Insert guide thorn into the positioning piston.
Führungsdorn leicht einfetten.Stellkolben mit Führungsdorn einbauen.
Grease slightly guide thorn.Install positioning piston with guide thorn.
Dichtring ins Gehäuse einführen und in der Aufnahmenutplazieren. Dann Spannung lösen und Montagezange herausziehen. Lage des Dichtringes prüfen - eventuell mit dem
Finger egalisieren.Position the seal ring into the housing and place it into thegroove. Release the tension and withdraw the assembly tool.Check the position of the seal ring if necessary straightenusing a finger.
Dichtring mit Zangenschenkel nierenförmig zusammen-drücken. Die Verformung von Turcon-Dichtungen istsorgfältig vorzunehmen, damit die Dichtkanten nichtbeschädigt werden.
Press the seal ring into the kidney shape using the assemblytool. The deformation of the Turcon seal has to be done withcare so as not to damage the sealing edges.
Stellkolben, Triebwerk einbauen
Positioning piston, rotary group assembly
Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring
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Brueninghaus Hydromatik 27
Triebwerk einbauen
Installation of the rotary group
75 Stellkolben ins Gehäuse einsetzen.Hinweis:Stellkolben vor Einbau einölen.
Insert positioning piston into the housing.Instruction:Oil positioning piston before assembly.
Lager, Draht, Gleitstein und Gelenkstiftmontieren.Montagehilfe: z.B. - Klammer / Gummiringe / Fett
Assemble bearing, wire, gliding stoneand articulating pin.Assistance: Devices e.g. - Clamp / rubber rings / grease
77
76 Lagerschalenpaar einsetzen.
Insert bearing cup set.
78 Schwenkwiege komplett ins Gehäuse einsetzen.Auf korrekten Sitz der Schwenklager im Gehäuse "achten".
Montagehilfe ausbauen.
Insert completely swivel cradle into the housing.Pay attention for correct seat of the swivel cradle in
the housing.
Remove auxiliary device.
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28 Brueninghaus Hydromatik
Triebwerk einbauen
Installation of the rotary group
80 Gelenkstift montieren.
Fit joint pin.
Kontrolle: Sitz der Schwenklager in derLagerbahn.
Schwenkwiege mit Stellkolben verschwenken "Leicht-gängig".Mittig stellen mit Meßvorrichtung (Uhr oder Tiefenmaß)Punkt 1 und 2 kontrollieren - gleiches Maß.
Check: Location of the swivel-bearingin the bearing.
Swivel the swivel bearing by using the control piston"it should move easily".Centralise by using a measuring device (dial gaugeor depth measurement).Check points 1 and 2 - they should have the samedimension.
79
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30 Brueninghaus Hydromatik
Triebwerk einbauen
Installation of the rotary group
82 Neue Montageposition!Triebwelle mit Lager und Wellendichtring einbauen.
Assemble drive shaft with bearings and radial seal rings.
82
84 Scheibe 1, 2
Disc 1, 2
21
85 Kolben mit Rückzugeinrichtung montieren.Hinweis:Kolben, Gleitschuhe einölen.
Assemble piston with retaining plate.Note:Oil piston and piston pad.
83
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Brueninghaus Hydromatik 31
Triebwerk einbauen
Installation of the rotary group
86 Vorrichtung ausbauen.Zylinder mit Kolben und Rückzugeinrichtung einbauen.
Remove holding device.
Fit cylinder complete with pistons and retaining device.
87 Montagehilfe:Mit O-Ring Kolben festhalten.
Assembly aid:Hold the pistons by using an O-ring.
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32 Brueninghaus Hydromatik
89 Steuerplatte Rechtslauf - in Drehrichtung verdreht.Achtung!Geräuschkerben sind drehrichtungsbezogen eingeschliffen.
Control plate clockwise rotation - indexed in the directionof rotation.Note!Noise grooves are machined - in based on directionof rotation.
91 Zylinderflächen und DU-Lager einölen, neue O-Ringemit Fett einreiben und einsetzen.
Oil the running surfaces of the cylinder barrel andthe DU- bearing. Grease the O-rings and insertin grooves.
90 Steuerplatte Linkslauf - in Drehrichtung verdreht.Achtung!Geräuschkerben sind drehrichtungsbezogen eingeschliffen.
Control plate counter clockwise rotation - indexed
in the direction of rotation.Note!Noise grooves are machined - in based on directionof rotation.
92 Grundeinstellung - VerdrillschraubeA4VG...40 * = 24 ± 0,75 mm.A4VG...56 * = 21 ± 0,75 mm.
Basic setting - indexing screwA4VG...40 * = 24 ± 0,75 mm.A4VG...56 * = 21 ± 0,75 mm.
93 Zylinder nach unten drücken (1).Verdrillschraube einbauen (2).Kerbe in Montageposition.
Press the cylinder to the bottom (1).Screw in the indexing screw (2).Groove in mounting position.
Triebwerk einbauen
Installation of the rotary group
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Brueninghaus Hydromatik 33
Pumpe montieren
Assembly of the pump
94 Steuerplatte einsetzen - Rechtslauf.
Insert the control plate - clockwise rotation.
96 Lagerichtig aufsetzen.Hinweis:HW, HD, EP - Steuerplatte mit Fett aufAnschlußplatte.
Place in correct position.Note:HW, HD, EP - Put control plate with greasto the port block.
95 Steuerplatte einsetzen - Linkslauf.
Insert the control plate - Counter- clockwise rotation.
97 Schrauben über Kreuz anziehen.Verdrillschraube auf Markierung drehen.
Tighten screws (Cross-corner).Turn the indexing screw to marking.
98 Hilfspumpe montieren.
Assemble boost pump.
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34 Brueninghaus Hydromatik
Pumpe montieren
Assembly of the pump
99 Ansteuergerät montieren.
Mount control module.
100
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Brueninghaus Hydromatik 35
Anziehdrehmomente
Tightening torques
Anziehdrehmomente für Schaftschrauben(Metrisches ISO-Regelgewinde)
Die nebenstehenden Werte für An-ziehdrehmomente gelten nur für
Schaftschrauben mit metrischem ISO-
Regelgewinde und Kopfauflagemaßennach DIN 912, DIN 931 und DIN 933.
Außerdem gelten diese Werte nur für
leicht oder nicht geölte, unbehandelte
Oberflächen, sowie nur bei Verwen-
dung von Drehmoment- und Kraftbe-
grenzungsschlüsseln.
Festigkeitsklassen
Gewinde 8.8 10.9 12.9
größe Anziehdrehmoment(Nm)
M 3 1,3 2,0 2,3
M 4 3,1 4,5 5,3
M 5 6,1 8,9 10,4
M 6 10,4 15,5 18.0
M 8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M 20 430 620 720
M 22 580 830 970
M 24 740 1060 1240
M 27 1100 1550 1850
M 30 1500 2100 2500
Anziehdrehmomente für Verschlußschrauben VSTI(Metrisches Feingewinde)
Gewindegröße Bezeichnung Anziehdrehmoment(Nm)
M 8 x 1 VSTI 8 x 1 -ED/SA = 5
M 10 x 1 VSTI 10 x1 -ED = 10
M 12 x 1,5 VSTI 12 x 1,5 -ED = 20
M 14 x 1,5 VSTI 14 x 1,5 -ED = 30
M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 30
M 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 40
M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 50
M 22 x 1,5 VSTI 22 x 1,5 -ED = 60
M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 70
M 27 x 2 VSTI 27 x 2 -ED = 90M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 100
M 33 x 2 VSTI 33 x 2 -ED/SA = 120
M 42 x 2 VSTI 42 x 2 -ED/SA = 200
M 48 x 2 VSTI 48 x 2 -ED = 300
Die nebenstehenden Werte für An-
ziehdrehmomente gelten nur für Seal-
Lock Bundmuttern der Festigkeits-
klasse 8.8 mit metrischem ISO-Regel-
gewinde.
Festigkeitsklassen
Gewinde 8.8 10.9 12.9
größe Anziehdrehmoment (Nm)
M 6 10
M 8 22
M 10 40M 12 69
M 14 110
M 16 170
Anziehdrehmomente für Seal-Lock Bundmuttern(Metrisches ISO-Regelgewinde)
Festigkeitsklassen
Gewinde 8.8 10.9 12.9
größe Anziehdrehmoment(Nm)
M 3 1,1
M 4 2,9
M 5 6
M 6 10
M 8 25
M10 49
Die nebenstehenden Werte für An-
ziehdrehmomente gelten nur für Lin-
senschrauben mit Kreuzschlitz DIN
7985 der Festigkeitsklasse 8.8 mit
metrischem ISO-Regelgewinde
Anziehdrehmomente für Linsenschrauben mit Kreuz-schlitz DIN 7985
(Metrisches ISO-Regelgewinde)
Strength Classes
Thread 8.8 10.9 12.9
size Tightening T orque(lb.ft)
M 3 1,3 2,0 2,3
M 4 3,1 4,5 5,3
M 5 6,1 8,9 10,4
M 6 10,4 15,5 18.0
M 8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M 20 430 620 720
M 22 580 830 970
M 24 740 1060 1240
M 27 1100 1550 1850
M 30 1500 2100 2500
Tightening torques for shaft bolts(Metric ISO Standard Thread)
The values for tightening torques
shown in the table are valid only for
shaft bolts with metric ISO- standard
threads and head support surfacedimensions in accordance with DIN 912,
DIN 931 and DIN 933. These values are
also valid only for light or unoiled,
untreated surface as well as for use only
with torque-indicating
wrenches and force limiting tools.
Tightening torques for locking screws VSTI(Metric ISO fine thread)
Thread size Designation Tightening torques (lb.ft)
M 8 x 1 VSTI 8 x 1 -ED/SA = 4
M 10 x 1 VSTI 10 x1 -ED = 7
M 12 x 1,5 VSTI 12 x 1,5 -ED = 15
M 14 x 1,5 VSTI 14 x 1,5 -ED = 22
M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 22
M 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 29
M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 37
M 22 x 1,5 VSTI 22 x 1,5 -ED = 44
M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 51
M 27 x 2 VSTI 27 x 2 -ED = 66M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 74
M 33 x 2 VSTI 33 x 2 -ED/SA = 88
M 42 x 2 VSTI 42 x 2 -ED/SA = 147
M 48 x 2 VSTI 48 x 2 -ED = 220
The values for tightening torques shown
in the table are valid only for seal-lock
nuts of the strength class 8.8 and with
metric ISO-standard thread.
Strength classes
Thread 8.8 10.9 12.9
size Tightening torque (lb.ft)
M 6 7,4
M 8 16,2
M 10 29,5M 12 50,9
M 14 81,1
M 16 125,3
Tightening torques for seal-lock nuts(Metric ISO-Standard Thread)
Strength classes
Thread 8.8 10.9 12.9
size Tightening torques (lb.ft)
M 3 0,8
M 4 2,1
M 5 4,4
M 6 7,4
M 8 18,4
M10 36,1
The values for tightening torques shown
in the table are valid only for cross-
slotted lens head screws DIN 7985 of the
strength class 8.8 and with metric ISO-
standard thread.
Tightening torques for cross-slotted lens head screwsDIN 7985
(Metric ISO- Standard Thread)
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36 Brueninghaus Hydromatik
General advice
· Make yourself familiar with the equipment of the
machine.· Only operate the machine if your are completely
familiar with the operating and control elements as
well as the functioning of the machine.
· Use your safety equipment like helmet, safety shoes
and hearing protection.
· Make yourself familiar with your working field.
· Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional
Association and the machine manufacturer.
Before starting
· Observe the operating instructions before starting.
· Check the machine for obvious faults.
· Do not operate the machine with defective
instruments, warning lights or control elements.
· All safety devices must be in a secure position.
· Do not carry with you movable objects or securethem to the machine.
· Keep oily and inflammable material away from the
machine.
· Before entering thc driver’s cabin, check if persons
or obstacles are beside or beneath the machine.
· Be careful when entering the driver’s cabin, use
stairs and handles.
· Adjust your seat before starting.
Sicherheitsbestimmungen
Safety regulations
Allgemein
· Machen Sie sich mit der Ausstattung der Maschine
vertraut.· Fahren Sie die Maschine nur, wenn Sie sich völlig
mit den Bedien- und Steuerelementen sowie der
Arbeitsweise der Maschine vertraut gemacht haben.
· Benutzen Sie Ihre Schutzausrüstung wie
Schutzhelm, Sicherheitsschuhe und Gehörschutz.
· Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
· Benutzen Sie die Maschine nur für den ihr zuge-
dachten Zweck.
Beachten Sie bitte die Richtlinien der Berufsge-
nossenschaft und des Maschinenherstellers
Vor dem Start
· Beachten Sie die Bedienungshinweise vor dem
Starten.
· Prüfen Sie die Maschine auf auffällige Fehler.
· Fahren Sie die Maschine nicht mit defekten
Instrumenten, Kontrolleuchten oder Steuerorganen.
· Alle Schutzvorrichtungen müssen fest auf ihremPlatz sein.
· Nehmen Sie keine losen Gegenstände mit bzw.
befestigen Sie diese an der Maschine.
· Halten Sie die Maschine von öligem und zünd-
fähigem Material frei.
· Prüfen Sie vor dem Besteigen der Maschine, ob
sich Personen oder Hindernisse neben oder unter
der Maschine befinden.
· Vorsicht beim Besteigen der Maschine, benützen
Sie Treppen und Griffe.
· Stellen Sie vor dem Start Ihren Sitz ein.
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Brueninghaus Hydromatik 37
Start
· When starting all operating levers must be in
“neutral position”.
· Only start the machine from the driver’s seat
· Check the indicating instruments after start toassure that all functions are in order.
· Do not leave the machine unobserved when the
motor is running.
· When starting with battery connection cables
connect plus with plus and minus with minus.
Always connect negative (-) cable last and
disconnect negative cable first.
Attention
· Exhaust gas is dangerous. Assure sufficient freshair when starting in closed rooms!
Hydraulic equipment
1. Hydraulic equipment is standing under high
pressure.
High pressure fluids (fuel, hydraulic oil) which
escape under high pressure can penetrate the
skin and cause heavy injuries.
Therefore immediately consult a doctor asotherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary
devices because of the danger of accidents.
3. Before working at the hydraulic equipment, lower
pressure to zero and lower working arms of the
rnachine.
4. When working at the hydraulic equipment, absolutely
stop motor and secure machine against rolling away
(parking brake, shim)!
5. When connecting hydraulic cylinders and motor pay
attention to correct connection of hydraulic flexiblehoses.
6. In case of exchanging the ports, the tunctions are
vice versa (f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace
them in case of dammage or wear! The new hose
pipes must comply with the technical requirements
of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
Sicherheitsbestimmungen
Safety regulations
Starten
· Beim Starten müssen alle Bedienhebel in “Neutral-
stellung” stehen.
· Die Maschine nur vom Fahrersitz aus Starten.
· Prüfen Sie die Anzeigeinstrumente nach dem Start,um sicher zu gehen, daß alles ordnungsgemäß
funktioniert.
· Lassen Sie die Maschine nicht unbewacht, während
der Motor läuft.
· Beim Start mit Batterieverbindungskabeln verbinden
Sie Plus mit Plus und Minus mit Minus. Massekabel
(Minus) immer zuletzt anschliesen und zuerst ab-
trennen.
Vorsicht
· Auspuffgase sind lebensgefährlich. Bei Start ingeschlossenen Räumen für ausreichende Luftzufuhr
sorgen!
Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!
Unter hohem Druck austretende Hochdruck-
Flüssigkeiten (Kraftstoff, Hydrauliköl) können
die Haut durchdringen und schwere Ver-
letzungen verursachen. Daher sofort einen
Arzt aufsuchen, da anderenfalls schwereInfektionen entstehen können!
2. Bei der Suche nach Leckstellen wegen Ver
letzungsgefahr geeignete Hilfsmittel verwenden!
3. Vor Arbeiten an der Hydraulikanlage diese un-
bedingt drucklos machen und angebaute Geräte
absenken!
4. Bei Arbeiten an der Hydraulikanlage unbedingt
Motor abstellen und Maschine gegen Wegrollen
sichern (Feststellbremse, Unterlegkeil)!
5. Beim Anschließen von Hydraulikzylindern und
-motoren ist auf vorgeschriebenen Anschluß derHydraulikschläuche zu achten!
6. Bei Vertauschen der Anschlüsse umgekehrte
Funktionen (z.B. Heben/Senken) - Unfallgefahr!
7. Hydraulikschlauchleitungen regelmäßig kontrol-
lieren und bei Beschädigung und Alterung aus-
tauschen! Die Austauschschlauchleitungen müs-
sen den technischen Anforderungen des Geräte-
herstellers entsprechen!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
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38 Brueninghaus Hydromatik
Einstellhinweise - Mechanische "Nullage"
Adjustment instructions - Mechanical "zero position"
Achtung!Sicherheitsbestimmungen beachten!Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignalaus hydraulischer Nullage.Manometer an M
A und M
B anschließen.
Nullage so einstellen, daß bei blockiertemAntrieb beide Manometer auf gleichem Druck-wert stehen.Hinweis:Totband der Nullage - vermitteln.
Attention!Observe safety regulations!Connect both control chambers with hoseNW6. Avoidance of rest signal from hydraulic
zero position.Connect manometer to M
A and M
B. Adjust
zero position so that at blocked drive bothmanometer indicate the same pressure valve.Note:Adjust death line of zero position.
102
HW HD EP DA
101
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40 Brueninghaus Hydromatik
Einstellhinweise - ND-Ventil (Speisedruck)
Adjustment instructions - Low pressure valve (Boost pressure)
Achtung!Sicherheitsbestimmungen beachten!
Hinweis:Nachjustierung nur bei Betriebstemperatur.
Manometer an "G" anschließen.
Achtung!* Speisedruckeinstellung!Nenndruck p
H - 18 bar
Höchstdruck pH - 40 bar
Bei Max.-Drehzahl.
Hinweis:Einstelldaten nach Werksauftrag.
* bei DA-Ausführung
Attention!Observe safety regulations!
Note:
Readjusting only at operating temperature.
Connect manometer to "G".
Attention!* Boost pressure setting!Nominal pressure p
H - 18 bar
Peak pressure pH - 40 bar
at max. speed.
Note:Adjusting data according to order.
105
"G"*
*
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Brueninghaus Hydromatik 41
Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung
Adjustment instructions - HP- valves (High pressure) and pressure cut-off
Achtung!Sicherheitsbestimmungen beachten!
HD-Ventil ohne Bypass
1 . HD- Ventile sind immer 10% höher eingestellt als dieDruckabschneidung.Bei Veränderung eines Einsteilwertes immer beidekontrollieren.2. Nachjustierung nur bei Betriebstemperatur
Manometer an MA und M
B anschließen.
Druckabschneidung: Maß X Einstellschrauben notieren!Einstellschraube auf Block drehen.
HD- Ventile: Mit geringer Pumpenmenge über Ventilefahren. Einstellwert kontrollieren.(Nur kurzzeitig "Temperatur“.)Drucklos "Einstellwert“ verändern - Kontrolle
Druckabschneidung:Einstellschraube auf Maß (*) zurückdrehen.Druckwert kontrollieren bzw. nachjustieren.Achtung! Differenz von 10% HD- Ventile undDruckabschneidung beachten!Hinweis: Einstelldaten nach Werksauftrag.
DruckabschneidungPressure cut-off
HD- VentileHP- valves
107
106
Attention!Observe safety regulations.
HP valve without bypass-function
1 . HP valves are always adjusted 10% higher than thepressure cut-off.If one setting value is changed, always check bothvalues.2. Readjusting only at operating temperature.
Connect manometer MA and M
B.
Pressure cut-off: Note measure X setting screw! Turnsetting screw on block.HP valves: Operate valves with small pump flowvolume.Check setting value. ("temperature“ only for a shorttime).Change "setting value“ - check.
Pressure cut-off:Turn back setting screw to measure (*).Check pressure value and readjust.Attention! Observe 10% pressure difference HP valves
and pressure cut-off!
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42 Brueninghaus Hydromatik
Einstellhinweise - Bypassventil
Adjustment instructions - Bypass valve
Vehicle with hydrostatic transmission and gear shiftwithout idling setting position (free wheeling).
Hydrostatic transmission / Bypass-switching
In this case the travel transmission is switched on tofree wheeling.For this purpose the variable displace-ment pump has incorporated high pressure relief valves
with bypass function.The screw (item 1) is unscrewed to such an extent, thatthe valve cartridge is released and free oil circulation ispossible.
Bypass: Screw in item1 up to planeness with nut. Screw up nut again.
Towing speedThe max. towing speed of 2 km/h should not beexceeded.
- Higher admissible towing speeds depend on theavaiable hydr. motor speed and engagedgear shift.
Towing distanceThe towing distance should not exceed 1 km.
- If there is a lack of oil boosting, the hydrauliccircuit will get empty.Take care of the heat development in the hydr.motor-rotary group.
Towing operation terminatedAfter termination of the towing operation turn item 1back. The original pressure value setting of the highpressure relief valves will be avaiable again.
Valve function: Screw back item 1 up to stop.
Screw up the nut.
Fahrzeuge mit rein-hydrostatischem Fahrantriebbzw. mit hydrostatischem Fahrantrieb und Schalt-getriebe ohne Leerlaufstellung (Freilauf).
Hydrostatischer Antrieb / Bypaß-Schaltung
In diesem Fall wird der Fahrantrieb auf freienUmlauf geschaltet. Zu diesem Zweck haben diein der Verstellpumpe integrierten Hochdruck-
begrenzungsventile eine sogenannte Bypaß-Funktion.D.h. durch Drehen der entsprechendenSchraube (Pos.1) wird der Ventil-Einsatz so entspannt,daß ein freier Öl-Umlauf möglich ist.
Bypass:Pos.1 einschrauben bis eben mit Mutter.Mutter wieder anziehen.
SchleppgeschwindigkeitDie maximale Schleppgeschwindigkeit sollte2 km/h nicht überschreiten.
- Höhere zulässige Schleppgeschwindigkeitensind abhängig von der Hydromotordrehzahlbzw. dem eingelegten Gang.
AbschleppdistanzDie Schleppentfernung sollte 1 km nicht überschreiten.
- Bei fehlender Einspeisung entleert sich derHydraulik-Kreislauf.Zu beachten ist die Wärmeentwicklung imHydromotor-Triebwerk.
Abschleppvorgang beendetNach beendetem Abschleppvorgang Pos.1 zurück-drehen. Der ursprüngliche Einstellwert der Hochdruck-ventile liegt somit wieder vor.
Ventilfunktion: Pos.1 zurückschrauben bis
Anschlag. Mutter anziehen.
108
1
11
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Reparaturanleitung A4VG
Repair Instructions A4VG
RDE 92003-01-R/05.99
44 Brueninghaus Hydromatik
Attention!Observe safety regulations!
Check setting data.Operating temperature should be kept largelyconstant during the check procedure.Start prime mover, idle speed.
Block positionDrive direction switch - "0“.Slowly increase motor speed up to the max.motor speed and thereby observe measuringinstruments.
Boost pressure:
Idle speed of prime moverPsp = approx. 15 - 20 barmax. motor speedPsp = . . . . . . . . . bar*
Block positionDrive direction switch - forward(Road gear and fully applied brake)
Check setting data pump A4VIDABegin of control:HD 40 - 50 barMotor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*Readjusting - control start screw
End of controlHD . . . . . . . . barMotor speed . . . . . . rpm* Psp . . . . . . . bar*Readjusting timing adjustment screw
Note:Eccentric adjusting - observe direction ofrotation
* Setting data according to order!
Einstellhinweise - DA- Regelung
Adjustment instructions - DA control
112
Begin of control
111
Timingadjustment screw
Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Telex 712538, Fax (07308) 7274
Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Telex 765321, Fax (07451) 8221
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7.2 A10VG
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Reparaturanleitung / Repair instructionsA10VG ... 28-63 Baureihe/Series 10
RDE 92750-01-R/10.01ersetzt/replaces 07.97
Mobile Hydraulics
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
2 Brueninghaus Hydromatik
HINWEIS
Bezeichnungen, Beschreibungen und Darstellungen
entsprechen dem Informationsstand zum Zeitpunkt derDrucklegung dieser Unterlage.
Änderungen können den Service am Produkt beein-flussen, Verpflichtungen entstehen uns daraus nicht.Methoden und Vorrichtungen sind Empfehlungen, fürderen Resultat wir keine Haftung übernehmen können.BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga-be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu-ren.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur aufdem Teststand vorzunehmen.
Schutz von Personen und Eigentum ist durch Vor-kehrungen sicherzustellen.
Sachkenntnis, die Voraussetzung für jede Service-arbeit,vermitteln wir in unseren Schulungskursen.
INHALT Seite/Page
A10VG
Schnittbild 3-4Allgemeine Reparaturhinweise 5Dichtsätze und Baugruppen 6-8Triebwelle abdichten 9Hilfspumpe abdichten 10-12Stellkolbendeckel abdichten 13Ventile abdichten 14Druckabschneidung abdichten 15Regelventil abdichten 16Steuergerät demontieren 17
Ansteuergeräte 18-22Pumpe demontieren 23-25Triebwerk ausbauen 26Stellkolben demontieren 27-28Überprüfungshinweise 29-31Turcon-Glyd-Ring montieren 32Pumpe montieren 33-35Triebwerk einbauen 36-38Pumpe montieren 39Montageanweisung für Anziehdrehmomente 40-43Sicherheitsbestimmungen 44-45Einstellhinweise 46-52
NOTICE
Specifications, descriptions and illustrative material
shown herein were as accurate as known at the time thispublication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right todiscontinue models or options at any time or to changespeci-fications, materials, or design without notice andwith-out incurring obligation.
Optional equipment and accessories may add cost to thebasic unit, and some options are available only incombination with certain models or other options.
For the available combinations refer to the relevant datasheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the testbench under operating temperatures.
Protection of personnel and property has to be guar-anteed by appropriate measures.
Expert knowledge, the precondition of any service work,can be obtained in our training courses.
CONTENTS
A10VG
Sectional viewGeneral repair instructionsSeal kits and sub assembly groupsSealing of the drive shaftSealing of the boost pumpSealing of the control piston coverSealing of the valvesSealing of the pressure cut-off valveSealing of the regulator valveRemoval of the control unit
Control unitsPump disassemblyRemoval of the rotary groupDisassembly of the positioning pistonInspection notesTurcon-Glyd-ringAssembly of the pumpInstallation of the rotary groupAssembly of the pumpAssembly guidelines for tightening torquesSafety regulationsAdjustment instructions
Hinweis / Inhalt
Notice / Contents
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 3
Schnittbild
Sectional view
HW
EPDHDD
mit Druckabschneidungwith pressure cut-off
ohne Druckabschneidungwithout pressure cut-off
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
4 Brueninghaus Hydromatik
Schnittbild
Sectional view
DA
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 7
Ansteuergerät HW
Control unit HW
Ansteuergerät HD
Control unit HD
Ansteuergerät HWmit Nullagenanzeige
Control unit HWwith zero indicator
AnsteuergerätEP
Control unit EP
Ansteuergerät DA
Control unit DA
Dichtsätze und Baugruppen
Seal kits and sub-assemblies
alt / old
neu / new
alt / old
neu / new
alt / old
neu / new
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
8 Brueninghaus Hydromatik
Dichtsätze und Baugruppen
Seal kits and sub-assemblies
Hilfspumpe mit Verschleißplatte
Boost pump with wear plates
Druckabschneidung
Pressure cut-off
1. DA - Regelventil, verstellbar mit Hebel2. DA - Regelventil, festeingestellt3. Zuschaltventil
1. DA control valve, adjustable via a lever2. DA control valve, fixed3. Switching valve
1. HD - Ventil2. HD - Ventil mit Bypass3. ND - Ventil
1. High pressure valve2. High pressure valve with bypass function3. Low pressure valve
1 2
32
1
3
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 15
Druckabschneidung abdichten
Sealing of the pressure cut-off valve
Wechsel der Dichtmutter.Einstellmaß festhalten (*).
Exchanging the sealing nut.Ascertsion the adjustment dimension (*).
Achtung!Nach Einbau "Ventileinstellung" überprüfen.
Attention!After assembly check "valve setting".
*
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
18 Brueninghaus Hydromatik
Ansteuergeräte
Control units
Ansteuergerät HW
HW control unit
NG / Size 28
NG / Size 45
Ansteuergerät DA
DA control unit
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Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 19
Ansteuergerät HD - EP altHD - EP control unit old
EP alt / old
Ansteuergeräte
Control units
HD alt / old
EP alt / old
HD alt / old
214,4 mm
202,0 mm
131,0 mm
77,4 mm
Neues Ansteuergerät HD - EPNew HD - EP control unit old
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
20 Brueninghaus Hydromatik
Ansteuergeräte
Control units
Ansteuergerät HD neuHD - control unit new
Ansteuergerät EP neuEP - control unit new
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 23
Pumpe demontieren
Pump disassembly
Druckabschneidung
Pressure cut-off
Excenterschraube
Eccentric screw
EP alt/old
EP neu/new
DA neu/newDA alt/old
HD alt/old
HD neu/new
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 43
Montageanweisung für Anziehdrehmomente
Assembly guidelines for tightening torques
A10V - Düsen / orifices
Gewinde / Anziehdremomente Nm /
ThreadTightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12
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Reparaturanleitung A10VG
Repair Instructions A10VG
RDE 92750-01-R/10.01
46 Brueninghaus Hydromatik
Einstellhinweise - Mechanische "Nullage"
Adjustment instructions - Mechanical "zero position"
Achtung!Sicherheitsbestimmungen beachten!Mit Schlauch NW6 beide Stellkammernverbinden. Vermeidung von Restsignalaus hydraulischer Nullage.Manometer an M
A und M
B anschließen.
Nullage so einstellen, daß bei blockiertemAntrieb beide Manometer auf gleichem Druck-wert stehen.Hinweis:Totband der Nullage - vermitteln.
Attention!Observe safety regulations!Connect both control chambers with a nominalsize 6 hose. Avoidance of residual signals fromhydraulic zero position.Connect pressure gauges to M
A and M
B. Adjust
the zero position so that with at blocked driveboth pressure gauges indicate the samepressure valve.Note:Ascertain the zero position dead band.
HW
HD
HWmit NullagenschalterHW with zero position switch
EP
DA
neu / new
alt / old
neu / new
alt / old
neu / new
alt / old
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Repair Instructions A10VG
RDE 92750-01-R/10.01
Brueninghaus Hydromatik 47
HW
Einstellhinweise - Hydraulische "Nullage"
Adjustment instructions - Hydraulic "zero position"
Manometer an X1 und X2 anschließen.Nullage so einstellen, daß bei blockiertemAntrieb beide Manometer auf gleichem Druck-wert stehen.Hinweis:Excenterjustierung- nicht über ±90° verdrehen.
Connect pressure gauges to X1 and X2.Adjust the zero position so that with a blockdrive both pressure gauges indicate thesame pressure value.Note:Eccentric adjusting- Do not turn more than ±90°.
Achtung!Sicherheitsbestimmungenbeachten!
Attention!Observe safety regulations!
EPneu/new
HW mit NullagenschalterHW with zero positionswitch
EPalt/old
HDneu/new
HDalt/old
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Repair Instructions A10VG
RDE 92750-01-R/10.01
48 Brueninghaus Hydromatik
Einstellhinweise - ND-Ventil (Speisedruck)
Adjustment instructions - Low pressure valve (Boost pressure)
Attention!Observe safety regulations!
Note:Readjusting only at operating temperature.
Connect pressure gauge to "G".
Attention!* Boost pressure setting!Nominal pressure pH - 18 barPeak pressure pH - 40 barat max. speed.
Note:Setting data is in accordance to the works order.
* with the DA version
Achtung!Sicherheitsbestimmungen beachten!
Hinweis:Nachjustierung nur bei Betriebstemperatur.
Manometer an "G" anschließen.
Achtung!* Speisedruckeinstellung!Nenndruck pH - 18 barHöchstdruck pH - 40 barBei Max.-Drehzahl.
Hinweis:Einstelldaten nach Werksauftrag.
* bei DA-Ausführung
*
"G"*
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MSHydraulikmotorenHydraulic motors
Reparaturen
Repairs
Ref : 800378128J
REPAR MS2-18 D/GB
Rev : A - Avr - 00
POCLAIN HYDRAULICS Industrie
B.P. 106 60411 VERBERIE CEDEX - FRANCE Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 www.poclain-hydraulics.com
POCLAIN HYDRAULICS
Certifié ISO 9001
02 05 08 11 18MS
MSE
StörungsbeseitigungTrouble Shooting
WartungsarbeitenMaintenance
ReparaturenRepairs
ErsatzteileSpare Parts
5767
0549 5766
0550
0545 5763
5764
5765
0547
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POCLAIN HYDRAULICS
2 REPAR MS2-18 D/GB 800378128J
Dieses Dokument richtet sich an die Hersteller von Maschinen und Sy-stemen, die Produkte von POCLAIN-HYDRAULICS einbauen, derenArtikelnummer auf der Titelseite genannt sind. Es beschreibt die Instal-lationsangaben und den Inbetriebnahmevorgang, damit ihre optimaleFunktionsweise gewährleistet wird.Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer an-gemessene Ausbildung durchgeführt werden. Sie müssen die Informa-tionen in diesem Dokument gelesen und verstanden haben und vom
Hersteller der Maschine bevollmächtigt sein.Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheitund zur Unfallverhütung beachten.
Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werdenauf folgende Weise gekennzeichnet:
! Sicherheitshinweis.
Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Be-trieb des Produkts sowie allgemeine Informationen. Sie werden auf fol-gende Weise gekennzeichnet:
Wesentliche Anweisung.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer-den, die auf die Anwendung der in diesem Dokument empfohlenen Ver-fahren zurückgehen.POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktionund die Betriebsbedingungen der Maschinen und Systeme, die mit PH-Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we-der für die Folgen eines falschen Einbaus der Produkte noch für ein fal-sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll-ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau-chern von den Maschinenherstellern zur Verfügung gestellt worden sind,verantwortlich.Jegliche Änderung einstellbarer Parameter der PH Produkte kann eineNeuzulassung der Maschinen erforderlich machen.Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY- DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY- DRAULICS prüfen und freigeben zu lassen.Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nurOriginal-Ersatzteile von POCLAIN HYDRAULICS . Die Montage vonTeilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy-stems sowie die Sicherheit beeinträchtigen.
Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sichPOCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigungalle Änderungen vorzunehmen, die als nützlich für die in diesem Doku-ment beschriebenen Produkte bewertet werden.Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab-schnitte, die Übersetzung in englischer Sprache darstellen.
Im Zweifelsfall ist die französische Version ausschlaggebend.Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungenin anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter-richtung angegeben.Die Abbildungen haben unverbindlichen Charakter.
POCLAIN HYDRAULICS Industrie 1998.Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von PO- CLAIN HYDRAULICS SA.Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Indu-strie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftli-ches Einverständnis weder gesamt noch teilweise verwendet, vervielfäl-tigt, kopiert oder an Dritte weitergegeben werden.FACOM ist ein eingetragenes Warenzeichen der FACOM SA.LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA.AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.
This document is provided to machine manufacturers integrating PO- CLAIN-HYDRAULICS products.. It suggests processes that manufac- turers may utilize to repair products after the warranty period.
It is recommended that all operations be performed by technicians trained accordingly. The technicians should read and understand the information given in this document and be authorized by the machine manufacturer.It is essential that the technicians comply with safety instructions to pre- vent injury.
This document includes major safety warnings announced in this way:
! Safety warning.
Additionally, this document includes instructions essential to product function as well as those providing general information. Both are an- nounced similar to the following examples:
Essential instruction.
General information.
POCLAIN HYDRAULICS designs products that are integrated by its customers in the machines they design.
Subsequently POCLAIN HYDRAULICS disclaims liability for conse- quences of improper integration of its products and of improper set-up of adjustable devices. In the same way, POCLAIN HYDRAULICS may not be liable for incomplete or improper operating and maintenance in- structions provided to the end user by the machine manufacturer nor for failures resulting from operations performed by any person using these suggested procedures.
A re-certification of the machine may be required for every change in set-up of adjustable devices.
In order to offer the best quality service, POCLAIN HYDRAULICS rec- ommends to its customers to have applications approved by POCLAIN HYDRAULICS.Opening of products voids the warranty contract.Use only POCLAIN HYDRAULICS genuine spare parts. Using parts from different sources could reduce the performance of the product and pose a safety hazard..
In accordance with its policy of continuous improvement, POCLAIN HYDRAULICS reserves the right to modify the specifications of all products described herein without prior notice.
This document contains sections written in German and sections printed in italics composing the English translation of the French sec-
tions. The French sections will be the reference in case of dispute.All measures are expressed in metric units. Converted values to other systems (notably US and UK) are given for reference only.
The illustrations for information only.
© POCLAIN HYDRAULICS Industrie 1998.The trademark POCLAIN HYDRAULICS is the property of POCLAIN HYDRAULICS S.A.This document is the property of POCLAIN HYDRAULICS Industrie.It is strictly confidential. It must not be used, duplicated, copied or dis- closed to a third party in full or in part without our prior written consent.FACOM is FACOM SA registered trademark.LOCTITE is LOCTITE SA registered trademark.AUTO-TOP is AGIP SPA registered trademark.
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 3
Inhaltsverzeichnis
INHALTSVERZEICHNIS ............................................. 3
SICHERHEIT UND QUALITÄT ................................... 4
VOR DEN WARTUNGSARBEITEN ....................................... 4WÄHREND DER WARTUNGSARBEITEN............................... 4NACH DEN WARTUNGSARBEITEN ..................................... 4IDENTIFIZIERUNG DES BAUTEILS....................................... 5
STÖRUNGSBESEITIGUNG........................................ 6
WARTUNGSARBEITEN.............................................. 8
AUSTAUSCHEN DES MOTORS........................................... 8Ausbau..................................................................... 8Einbau...................................................................... 8
MECHANISCHE BREMSLÖSUNG ........................................ 9KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10
REPARATUREN. ...................................................... 11
AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11Demontage ............................................................ 11Wiedereinbau......................................................... 13
AUSWECHSELN DES LAGERTEILES (070)......................... 16Demontage ............................................................ 16Wiedereinbau......................................................... 18
AUSWECHSELN DER BREMSBACKEN ............................... 20Demontage ............................................................ 20Wiedereinbau......................................................... 23
AUSWECHSELN DES NOCKENRINGS (026)....................... 27Demontage ............................................................ 27
Wiedereinbau......................................................... 27AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010)28Demontage ............................................................ 28Wiedereinbau......................................................... 28
AUSWECHSELN DES VERTEILERS (047). ......................... 29Demontage ............................................................ 29Wiedereinbau......................................................... 29
AUSWECHSELN DER DECKELDICHTUNG (045).................. 32Demontage ............................................................ 32Wiedereinbau......................................................... 33
AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34Demontage ............................................................ 34Wiedereinbau......................................................... 35
WERKZEUG-LISTE .................................................. 36Standard Werkzeug................................................ 36Spezialwerkzeuge .................................................. 37
ANZIEHDREHMOMENTE NM ± 10%........................... 38
ERSATZTEILE.......................................................... 39
MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 02-05-08-11-18. .............................................................. 42MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE02-05-08-11-18. ......................................................... 44
Contents
CONTENTS................................................................. 3
SAFETY AND QUALITY ............................................. 4
B EFORE SERVICING ........................................................ 4 D URING SERVICING ......................................................... 4 AFTER SERVICING ........................................................... 4 I DENTIFICATION OF THE COMPONENT ................................. 5
TROUBLE SHOOTING ............................................... 7
MAINTENANCE.......................................................... 8
R EPLACING THE MOTOR .................................................. 8 Removal................................................................... 8 Installation................................................................ 8
M ECHANICAL BRAKE RELEASE .......................................... 9 C HECKING THE PARKING BRAKE EFFICIENCY ..................... 10
REPAIRS. ................................................................. 11
R EPLACEMENT OF THE O- RING OF THE BRAKE PISTON ....... 11Disassembly........................................................... 11Reassembly. .......................................................... 13
R EPLACEMENT OF THE BEARING SUPPORT (070).............. 16 Disassembly........................................................... 16 Reassembly ........................................................... 18
R EPLACING THE BRAKE SHOES ....................................... 20 Disassembly........................................................... 20 Reassembly ........................................................... 23
R EPLACEMENT OF THE CAM (026) .................................. 27 Disassembly........................................................... 27
Reassembly ........................................................... 27 R EPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28
Disassembly........................................................... 28 Reassembly ........................................................... 28
R EPLACEMENT OF THE VALVING (047). ........................... 29 Disassembly........................................................... 29 Reassembly ........................................................... 29
R EPLACEMENT OF THE O- RING (045) OF THE END COVER . 32 Disassembly........................................................... 32 Reassembly ........................................................... 33
R EPLACING THE SENSOR ( OPTIONAL ) .............................. 34 Disassembly........................................................... 34 Reassembly ........................................................... 35
TOOLING INVENTORY............................................. 36
Standard tools ........................................................ 36 Special tools........................................................... 37
TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38
SPARE PARTS LIST ................................................ 39
S INGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-11- 18. ............................................................................. 42 D UAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44
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Sicherheit und QualitätVor den Wartungsarbeiten• Alle notwendigen Sicherheitsvorkehrungen treffen
(Menschen und Material) und die geltenden Sicher-heitsvorschriften beachten.
• Parkbremse betätigen und Maschine mit Keilenfestsetzen.
• Energieerzeugung (Motor) des Hydrauliksystemsabstellen und die Stromversorgung ausschalten.
• Gegebenenfalls eine Sicherheitszone einrichten.
• Die Außenflächen der Bauteile reinigen, umSchmutz und Fett restlos zu entfernen.
• Warten, bis das Hydrauliksystem vollständig abge-kühlt und druckentlastet ist (die Speicher entlasten).
!Das heiße oder unter Druck stehende Ölkann zu schweren Verbrennungen mitEntzündung führen.Bei einem Unfall einen Arzt hinzuziehen.
Während der Wartungsarbeiten• Bestimmte Bauteile sind sehr schwer. Sie müssenbei der Abnahme vom Rahmen mit einer angemessenausgelegten Hebevorrichtung gehalten werden.
• Die Sauberkeit ist wesentlich beim Betrieb der Hy-draulikbauteile. Die meisten Teile können mit einemsauberen Lösungsmittel gereinigt werden.
• Während der Handhabung alle empfindlichen Ober-
flächen gegen Stöße schützen (Zentrierungen, gleitendeTeile, Auflagen, Dichtungs- und Lagerauflagen usw.).
• Diese Flächen vor dem Wiederzusammenbau reinigen.
• Systematisch die demontierten Dichtungen beimWiederzusammenbau durch neue ersetzen. Wir emp-fehlen, vor der Montage alle Dichtungen zu fetten.
• Alle gleitenden Flächen durch Aufbringen eines Filmssauberer Hydraulikflüssigkeit ölen, der eine korrekteSchmierung beim ersten Neustart gewährleistet.
• Niemals die Hydraulikflüssigkeit, die sich bei hohenTemperaturen entzünden kann, erwärmen. Einige Lö-sungsmittel sind ebenfalls entzündlich.
Während der Arbeiten nicht rauchen.
Nach den WartungsarbeitenDie Bauteile wieder einbauen und das Hydrauliksystemgemäß den Anweisungen in den folgenden Dokumen-ten wieder in Betrieb nehmen:• INSTALLATION MS D/GB (ref: 800078173V)
• INSTALLATION CIRCUITS D/GB (ref. 677777853U)
!Die Einstellung der Sicherheitsventilenicht erhöhen.
Safety and Quality
Before servicing
• Be extremely careful to prevent personal injury and to avoid damage to material. Comply with all safety regulations.
• Apply the parking brake and prevent the machine from rolling with tire blocks.
• Stop the hydraulic system power source (engine)and disconnect the battery.
• If necessary, block off the safety area.
• Wash dirt and grease from exterior of the compo- nents.
• Await the complete cooling down and depressuriza- tion of the hydraulic system (accumulators must be purged).
!
Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body.Consult a physician in case of accident.
During servicing
• Some hydraulic components are very heavy. Se- cure them with a lifting device of adequate capacity when removing from the machine frame.
• Cleanliness is essential to functioning of the hy- draulic components. Most of the parts may be cleaned with a clean solvent.
•
During handling, protect all sensitive surfaces from
shocks (piloting and interface surfaces, thrust & bear- ings surfaces, seal races, etc...)
• Clean up these surfaces before reassembling.
• Always install new O-rings, seals & gaskets dis- carding the old ones. We recommend lubricating all seals prior to assembly.
• Lubricate all surfaces which have relative motion between parts by coating them with a film of clean hy- draulic fluid to assure lubrication at first start.
• Never heat hydraulic fluid, as it may flame at high
temperature. Some solvents are also flammable.
Do not smoke during servicing.
After servicing
Reinstall the components and restart the hydraulic system according to instructions defined in the following documents:
• INSTALLATION MS F/GB (ref . 677777844K )
• INSTALLATION CIRCUITS F/GB (ref . 677777831V )
! Do not overset relief valves.
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800378128J REPAR MS2-18 D/GB 5
Identifizierung des Bauteils Identification of the component
A : Handelsbezeichnung:Ex : MSE18-2-D11-F19-2A10-K000
B : Code :Artikelnr.:Ex : 000143896J
C : Serie :HerstellungsnummerEx : 001
D : Num : Chronologische OrdnungsnummerEx : 40712
Bei sämtlichen Ersatzteilbestellungenmüssen die Artikelnummer und die chro-nologische Ordnungsnummer angege-ben werden.
A: Commercial description: E.g : MSE18-2-D11-F19-2A10-K000
B: Code:Part number.E.g : 000143896J
C: Series: Manufacturing batch number.E.g : 001
D: Num: Chronological serial number.E.g : 40712
The part number and the chronological serial number must be specified to order
spare parts.
C
B D
A
0349
MS18-2-D11-F19-2A10-K000
000143896J
001 40712
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POCLAIN HYDRAULICS
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Störungsbeseitigung
BECHÄDIGUNG ABRIEB ERKENNUNG DURCH FILTER VORBEUGUNG……
Störung Ursachen Abhilfe
RegelmäßigesBrummen
Lagerteil verschlissen Lagerteil ersetzenOhneLast
VibrationenLockere Befestigungenund / oder Anschlüsse
Mit entsprechendem Drehmo-ment anziehen
Klappern Speisedruck zu niedrigSpeise- und Austauschdruck-
ventil kontrollieren.
LAUTE GERÄUSCHE DES
MOTORS
UnterLast
Kavitation Interne Lecks zu großZylinderblock und Ölverteiler
ersetzen
Der Motor wird nicht ver-
sorgt
Den Antrieb der Pumpe und ih-
re Versorgung überprüfenKein Druckanstieg im
KreisHochdruck-Begrenzungsventile
kontrollieren (Regler)
Interne Lecks zu großZylinderblock und Ölverteiler
ersetzen
MOTOR DREHT SICHNICHT
Die Bremse bleibt angezo-gen
Den Steuerkreis der Bremsekontrollieren
Der Fördermenge derPumpe ist unzureichend
Die Antriebsdrehzahl und denZustand der Pumpe kontrollie-
ren
Interne Lecks zu groß Den Zustand des Zylinder-blocks und des Ölverteilersüberprüfen
DER MOTOR DREHT
SICH NICHT MITNORMALER LAST-DREHZAHL
Der Betriebsdruck ist zuniedrig
Den Zustand des Sicherheits-ventils kontrollieren (Regler)
Die Fördermenge derPumpe schwankt
Steuerdruck und Fördermengeder Pumpe kontrollierenDER MOTOR DREHT
SICH UNREGEL-MÄSSIG Interne Lecks zu groß
Den Zustand des Zylinder-blocks und des Ölverteilers
überprüfen.
Gehäusedruck zu groß Den Leckagekreis und den Zu-stand des Filters überprüfen
Dichtungen beschädigt Die Dichtungen ersetzenÄUSSERE ÖLUN-DICHTIGKEITEN
Fehlerhafte Montage
Das Anziehmoment der Monta-geschrauben, der Entlüftungs-schrauben und der Anschlüsse
kontrollieren
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 7
Trouble shooting
DAMAGE IRON PARTICLES DETECTION BY FILTERS PREVENTION……
Troubles Causes Remedies
Regular rum- bling
Worm bearing support Replace the bearing support
Without load
Vibrations Mountings and/or hydraulic
piping becoming loose Tighten to torque
Clattering Boost pressure too low Check the setting and condi- tion of counter-pressure valve
NOISY MOTOR
Under load
Cavitation Excessive internal leaks Replace the cylinders- block and distribution valve assem-
bly
No supply to the motor Check pump drive and pump inlet
The circuit does not reach working pressure
Check condition of safety valve (regulator)
Excessive internal leaks Replace the cylinders block
and distribution valve assem- bly
THE MOTOR DOES NOT REVOLVE
The brake stays engaged Check the brake pilot circuit
Pump flow is too low Check drive speed and condi-
tion of the pump
Excessive internal leaks Check condition of cylinders- block and distribution valve
assembly
THE MOTOR DOES NOT REVOLVE AT ITS NORMAL SPEED
UNDER LOAD
Working pressure is too low
Check safety valve setting pressure (regulator)
Irregular flow Check the pump flow THE MOTOR RE- VOLVES IRREGU-
LARLY Excessive leaks Check condition of cylinders- block and distribution valve
assembly
Too high casing pressure Check the leakage circuit and
filter condition
Seals damaged Replace seals EXTERNAL OILLEAKS
Incorrect assembling Check tightening of mounting
screws, bleed screws and unions
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Wartungsarbeiten
Austauschen des Motors
Ausbau
• Druck im Arbeitskreis abbauen.• Leckageleitung am Tank abschrauben, um ein
Leerlaufen zu verhindern.• Die Rohre oder Schläuche, die am Motor ange-
schlossen sind, abklemmen.• Drehzahlsensor abklemmen.• Die Befestigungsschrauben demontieren und den
Motor ausbauen.• Das Motorgehäuse entleeren.
Einbau
Die zum Ausbau angegebenen Arbeitsgänge in umge-kehrter Reihenfolge ausführen.
Für weitere Informationen beziehen Sie sich bitte auffolgende Dokumente:• INSTALLATION MS D/GB (ref: 800078173V)• INSTALLATION CIRCUITS D/GB (ref: 677777853U)
Maintenance
Replacing the motor
Removal
• Release the pressure in the supply circuit.
• Disconnect the drain line at the tank level to avoid its siphoning.
• Disconnect and plug the pipes or hoses which are connected to the motor.
• Disconnect the speed sensor.
• Disconnect the mounting screws, and remove the motor.
• Drain the casing.
Installation
Execute the removal operations in the reverse order.
Please refer to the following documentation brochures:
• INSTALLATION MS F/GB (ref : 677777844K )
• INSTALLATION CIRCUITS F/GB (ref: . 677777831V )
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 9
Mechanische Bremslösung Mechanical brake release
Bei bestimmten Reparaturfällenoder zum Abschleppen der Maschi-ne muß die integrierte Parkbremse
gelöst werden.
In certain service situations, it may be necessary to release the motor brake.
• Stopfen (142) aus der Schutz-kappe (141) herausziehen.
• Extract and release the plug (142) from the brake cover (141).
• Schraube im Kolben festziehen • Tighten the screw in the piston
• Mutter so weit anziehen, bis dieWelle frei dreht.
• And tighten the nut until the motor shaft turns freely.
Bremsen Brakes Kraft N Force [lbf] Entsprechendes
Drehmoment NmEquivalent torque [lbf.ft] Mutter Nut
F02-F04 18000 [4.000] 42 [30.9] M12F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16
!Nach Bremslösung, einen neuen Stopfen(142) einbauen. !
After brake release, mount a new plug (142) .
6556
142
6499
6555
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POCLAIN HYDRAULICS
10 REPAR MS2-18 D/GB 800378128J
Kontrolle der statische Haltebremse.
!Bei fahrbaren Maschinen den Test auf ebenemGrund durchführen.
Bremssteuerdruck: mini 12 barMaxi 30 bar.
• Sich vergewissern, daß der Bremsversorgungs-druck gleich Null ist,• Die Bremse über die höchstgelegene Schraube(112) entlüften,• Den Motor mit Maximaldruck beaufschlagen,
• Die Motorwelle darf sich nicht drehen, da andern-falls die Bremse ausgetauscht werden muß :
! Mehrscheibenbremsen nicht einfahren.
Checking the parking brake efficiency.
!For a rolling machine, make the test on a hori- zontal ground .
Pilot brake pressure : minimum 12 bar [174 PSI] Maximum 30 bar [435 PSI]
Make sure that the brake supply pressure is zero,
• Purge the brake using the screw (112) located at the highest level,
• Supply the motor up to the setting pressure.
• The motor shaft must not turn, otherwise it is nec- essary to replace the brake :
! Do not run multidisc brakes in.
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 11
Reparaturen. Repairs.
Auswechseln der Brems-kolbendichtung
Demontage
Replacement of the O-ring of the brake piston.
Disassembly
• Den Motor ausbauen.• Motor auf das Lagerteil stellen.
!Muttern zum Schutz derGewindebolzen wiederaufsetzen
• Remove the motor.
• Place the motor on the bearing support.
!Protect the studs by reinstalling the nuts
• Schutzkappe (141) abnehmenund beseitigen.
• Remove and discard the brake cover.(141)
• O-Ring (143) herausziehen undbeseitigen.
• Extract and discard the O-ring (143).
• Tellerfeder (108) zusammen-drücken:
• Mit Hilfe des Dorns und Ab-ziehers (siehe Werkzeug Seite36) (fig 6502)• Mit Hilfe des Dorns und einer
Schraube Klasse 12.9 (sieheWerkzeug Seite 36)• Mit Hilfe des Dorns und einerPresse (fig 6503). Die Kraft Fbeibehalten (siehe SchaubildSeite 9)
Einsatzrichtung des Si-cherungsrings markieren.
• Compress the washer (108).
• Using a mandrel and an ex- tractor (see tools page 36)(fig 6502)
• Using a mandrel and a
screw class 12.9 (see tools page 36)
• Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)
Mark the mounting di- rection of the snap ring .
6500
6501
6502
6503
141
143
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POCLAIN HYDRAULICS
12 REPAR MS2-18 D/GB 800378128J
• Sicherungsring (109) mit Hilfeeiner Zange für Innenringe heraus-nehmen (siehe Werkzeuge Seite36)
• Abzieher und Zange (fig6504 und 6505)• Presse und Zange (fig 6506und 6507)
!
Bei Verwendung der Pres-se das Lagerteil nicht aufden Gewindebolzen ab-stützen.
• Remove the snap ring (109)using internal snap ring pliers. (see tools page 36)
• Extractor and pliers (fig 6504 and 6505)
•
Press and pliers (fig 6506 and 6507)
!If you use the press do not place the bearing support on the studs.
• Tellerfeder (108) herausziehen. • Extract the washer (108).
• Bremskolben (107) herauszie-hen.
• Extract the brake piston (107)
• O-Ring (106) beseitigen. • Discard the O-ring (106).
6504 6505
6506 6507
6508
6513
6511
108
106
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 13
Wiedereinbau.
Vor dem Wiedereinbau ist unbedingtsicherzustellen, daß alle Teile, Nutenund Dichtungs-Auflageflächen saubersind.
!Es dürfen keine Rost-,Schmutz- oder Wasser-spuren vorhanden sein
Mit Korrosionsschutzfett (sieheWerkzeug Seite 36) einschmieren:die Nut, die obere Fläche desBremskolbens, die Tellerfeder, denSicherungsring und die Auflageflächeder Kolbendichtung im Bremsgehäuse.
Reassembly.
Before reassembling, it is neces- sary to ensure that all parts, the surface condition of the piston seal contact surface and the grooves are clean.
!All traces of rust, mud,water must be removed.
Coat with anti-oxidizing grease (see tools page 36), the grooves, the top of the brake piston, the spring washer, the snap ring and the pis- ton seal contact surface in the brake body.
• Neuen O-Ring (106) auf den
Kolben (107) montieren.
!Der Ring muß fest anden Kolben gepreßt undnicht verdreht werden.
• Install a new O-ring (106) on
the piston (107).
!The ring should be tight on the piston and not twisted.
• Bremskolben (107) einsetzen.
!
Achtung, wenn dieDichtung über die Nut
des Sicherungsringsgeführt wird.
• Install the brake piston (107).
!
Take care when passing the seal over the snap ring groove.
• Tellerfeder (108) einlegen. Install the spring washer (108).
6512
6509
6513
107
108
106
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POCLAIN HYDRAULICS
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• Tellerfeder (108) zusammen-drücken:
• Mit Hilfe des Dorns und Ab-ziehers (siehe Werkzeug Seite36) (fig 6502)• Mit Hilfe des Dorns und einerPresse (fig 6503). Die Kraft Feinbehalten (siehe SchaubildSeite 9)
!
Bei Verwendung derPresse das Lagerteilnicht auf den Gewinde-bolzen abstützen.
• Compress the spring washer (108).
• Using a mandrel and an ex- tractor (see tools page 36)(fig 6502)
•
Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)
!If you use the press do not place the bearing support on the studs.
• Sicherungsring (109) mit Hilfeeiner Zange für Innenringe gemäßder bei der Demontage ange-brachten Kennzeichnung montie-ren: (siehe Werkzeuge Seite 36)
• Abzieher und Zange (fig6504 und 6505)• Presse und Zange (fig 6506und 6507)
• Install the snap ring (109) using internal snap ring pliers in line with the mark made during disassembly . (see tools page 36)
• Extractor and pliers (fig 6504 and 6505)
• Press and pliers (fig 6506 and 6507)
• Neuen, mit Korrosionsschutzfetteingeschmierten O-Ring (143) indie Nut einsetzen (siehe Werkzeu-ge Seite 36).
• Install a new O-ring (143)coated with anti-oxidizing grease in its groove. (see tools page 36)
• Neue Schutzkappe (141) aufden Anschnitt legen.
• Place the new cover (141) on the entry chamfer .
6503
6504 6505
6506 6507
6515
6516
6502
143
141
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 15
• Schutzkappe mit Hilfe desDorns einrasten lassen (sieheWerkzeug Seite 36).
!
Sich vergewissern, daßder Außenrand des
Schutzkappe in die Nuteingreift ist.
• Click the cover into place using the right mandrel. (see tools page 36).
!Make sure that the outer edge of the cover is en-
gaged in the groove.
• Neuen Stopfen (142) einsetzen.
!
Sich vergewissern, daßzwischen Schutzkappeund Stopfenrille ein-wandfreier Kontakt be-steht.
• Install a new plug (142).
!Make sure about the con- tact between the cover and the plug groove.
• Motor wieder einsetzen. • Install the motor.
6517
6518
142
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POCLAIN HYDRAULICS
16 REPAR MS2-18 D/GB 800378128J
Auswechseln des Lager-teiles (070)
Replacement of the bearing support (070)
Demontage Disassembly
Motor herausnehmen.Motor auf der Bremse oder Ver-schlussplatte abstützen (Motor ohneBremse).
Remove the motor.Place the motor on the brake or on the end cover (motor without brake).
• Position des Lagerteiles(070) in Bezug auf Nockenring(026) und Verteilerdeckel (040)kennzeichnen.
• Mark the position of the bearing support (070) in relation to the cam (026) and to the valving cover (040).
• Schrauben (042) heraus-nehmen.
• Remove the screws (042).
• Lagerteil (070) herausneh-men.
• Remove the bearing support (070).
• Nockenring (026) heraus-nehmen.
• Remove the cam (026).
6519
6520
6521
6524
070
025
040
042
070
026
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 17
• O-Ring (027) vom Verteiler-deckel (041) entfernen.
• Discard the O-ring (027)from the valving cover (041).
• O-Ring (027) vom Lagerteil(071) entfernen.
• Discard the O-ring (027)from the bearing support (071)
6522
6525
027
041
027
071
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POCLAIN HYDRAULICS
18 REPAR MS2-18 D/GB 800378128J
Wiedereinbau Reassembly
Vor dem Wiedereinbau ist unbe-dingt sicherzustellen, daß die Nutsauber ist
!Es dürfen keine Rost-,Schmutz- oder Wasser-spuren vorhanden sein.
Before reassembling it is necessary to ensure that the groove is clean
!All traces of rust, mud,water must be removed
• Neuen, mit Korrosions-schutzfett eingeschmierten O-Ring(027) in die Nut des Lagerteiles(071) einsetzen (siehe WerkzeugeSeite 36) .
• Install a new O-ring (027)coated with anti-oxidizing grease (see tools page 36) in the groove of the bearing support (071).
• Neuen, mit Korrosions-schutzfett eingeschmierten O-Ring(027) in die Nut des Verteilerdek-kels (041) einsetzen (siehe Werk-zeuge Seite 36) .
• Install a new O-ring (027)coated with anti-oxidizing grease (see tools page 36) in the groove of the valving cover (041)
• Nockenring (026) gemäß derbei der Demontage markiertenKennzeichnung montieren.
!Große Ansenkungen inRichtung Lagerteil
Den Nockenring anhand von zweieinander gegenüberliegendenSchrauben (042) zentrieren.
• Install the cam (026) in line with the marks made during disas- sembling.
!The big chamfers oriented towards bearing support
Center the cam using two screws (042) diametrically opposite.
6523
027
071
026
6526
041
6525
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 19
• Lagerteil montieren
!
Bei Wellenmotorenmüssen die Anschlüssequer zur Einbauachsedes Motors liegen.
(Abb. 6521)
• Install the bearing support
!
For shaft motors the ports must be perpen- dicular to the mounting axis of the motor. (Fig
6521)
• Befestigungsschrauben (042)einsetzen und mit dem angegebe-nen Drehmoment anziehen. (sieheSchaubild Seite 38).
• Install and tighten the mounting screws (042) to the right torque.(see table page 38).
• Motor wieder einsetzen. • Install the motor.
6521
6520
042
6527
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POCLAIN HYDRAULICS
20 REPAR MS2-18 D/GB 800378128J
Auswechseln der Brems-backen
Replacing the brake shoes.
Vor der Demontage kann man dieAbnutzung der Bremsbeläge durch
die Inspektionsöffnungen kontrollie-ren.
Before disassembling it is possible to make a visual checking of the
brake pads wear via the inspection ports.
Demontage Disassembly
!
Das Auswechseln desBremsbacken und dasSchleifen der Trommelnmuß auf allen Motorender gleichen Achse vor-genommen werden.
• Befestigungsmuttern der Felgelösen.• Maschine auf der Höhe derauszubauenden Felge hochheben.• Rad abnehmen (Reifen).• Mechanische Bremse lösen.
!
The same repairs should be made on each motor of the same axle when replacing shoes and brake drums .
• Loosen the wheel rim retaining nuts.
• Raise the machine on the side of the wheel rim to be removed.
• Remove the wheel rim (tyre).
• Release the mechanical brake.
• Trommel (096) abziehen.
!
Reibfläche der Trommelüberprüfen, die weder tiefeRillen (tiefer als 0,2 mm)noch abnormale Abnut-zungserscheinungen auf-weisen darf, sonst mußsie geschliffen werden.(Ra 1,6 bis 3,2)
• Extract the drum (096).
!
Check the friction sur- face condition of the drum which should show no deep scratches (deeper than 0,2 mm [0.0078 in]) nor abnormal wear. Otherwise, the brake drum should be replaced. (Ra 1.6 to 3.2)
2055
096
6528
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 21
• Rückholfeder (154.a) abbauen. • Remove the return spring (154.a).
• Halterungsfedern (154.b) ab-bauen.
• Remove the retention springs (154.b).
• Bremsbacken aus der Betäti-gungsvorrichtung lösen.
• Release the brake shoes from the regulating mechanism.
• Rückholfedern (154.c) abbau-en.
• Remove the return springs (154.c).
154.a
154.b
1
2
154.c
6529
6530
6531
6532
6533
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POCLAIN HYDRAULICS
22 REPAR MS2-18 D/GB 800378128J
• Bremsbacke (154.1) abbauen. • Remove the brake shoe (154.1)
• Den mechanischen Bremshebelvom Bremsseil lösen und Brems-backe (154.2) entfernen
• Releasing the mechanical brake control lever from its cable, remove the brake shoe (154.2)
154.1
154.2
6535
6536
6534
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 23
Wiedereinbau Reassembly
!
Vorrichtung entstau-ben, sich vergewissern,daß der Radzylinder
dicht ist.
Reibfläche der Trommel überprü-fen, die weder tiefe Rillen (tiefer als0,2 mm) noch abnormale Abnut-zungserscheinungen aufweisendarf, sonst muß sie geschliffenwerden.
!
Remove all dust from the whole assembly. Make sure there are no leaks at
the wheel cylinder.
Check the friction surface condition of the drum which should show no deep scratches (deeper than 0.2 mm) [0.0078in] nor abnormal wear.Otherwise, the brake drum should be replaced.
• Den Bremshebel am Bremsseil(098) befestigen und Bremsbacke(154.2) einbauen
• Attaching the control lever on the brake cable (098), install the brake shoe (154.2)
154.2
6535
6536
098
6549
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POCLAIN HYDRAULICS
24 REPAR MS2-18 D/GB 800378128J
• Rückholplatte an die Brems-backe (154.2) montieren.
• Mount the return plate on the brake shoe (154.2)
• Bremsbacke (154.1) einsetzen. • Install the brake shoe (154.1)
• Bremsbacken auf der Betäti-gungseinrichtung positionieren.
• Position the brake shoes on the regulating mechanism.
• Rückholfedern (154.c) einset-zen.
Install the return springs (154.c)
6537
6532
6533
154.c
6538
6539
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 25
• Bremsbacken in die Betäti-gungseinrichtung einbauen.
• Install the brake shoes in the regulating mechanism
• Halterungsfedern (154.b) ein-setzen.
• Install the retention springs (154.b).
• Rückholfedern (154.a) einset-zen.
• Install the return spring (154.a).
• Reibungsdurchmesser D derTrommel und der eingesetzten Ba-cken messen.
• Measure the brake drum friction diameter D and that of the brake shoes, which have been installed.
154.b
1
2
Durchmesser D diameter
6532
6531
6530154.a
6529
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POCLAIN HYDRAULICS
26 REPAR MS2-18 D/GB 800378128J
• Backendurchmesser anpassen,um bei Bremsen mit mechanischerEinstellvorrichtung mit Hilfe des ei-nen Zahnrads (156.1), oder beiBremsen mit automatischer Brem-sennachstellung mit Hilfe der zweiZahnräder (156.2 und 156.3), dasnötige Spiel zwischen Belag undTrommel zu erzielen. In diesemFall muß die Wirkung auf die Zahn-räder symmetrisch (a) sein. DenHebel (156.4) muss zu diesemZweck freigängig sein.
• Adjust the brake shoes diame- ter to obtain correct clearance be- tween the brake padding and the drum using the adjusting wheel (156.1) for brakes equipped with mechanical adjustment system or two adjusting wheels (156.2 and 156.3) for brakes equipped with automatic clearance adjustment. In this case, the adjusting wheels should be adjusted symmetrically (a). Release the lever slightly (156.4) to enable this operation to take place.
Trommeldurchmesser (mm)Drum diameter [in] Bremsen
Brake nominal maximum
Total Spiel (mm)Total clearance [in]
250 x 60 250 [9.84] 252 [9.92 ] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70 ] 0.80 [0.03]
325 x 80 325 [12.79 ] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]
• Trommel aufsetzen und über-prüfen, ob sie frei dreht.
• Install the drum, check that it can turn freely.
• Wenn nötig, den Radzylinderentlüften.• Felge montieren.Siehe Dokument INSTALLATIONMS D/GB (ref: 800078173V)
• Bleed the wheel cylinder, if necessary.
• Install the wheel rim.See documentation INSTALLATION MS F/GB (ref 677777844 K )
6540
6528
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 27
Auswechseln des Nocken-rings (026)
Demontage
Dazu die im Kapitel « Auswechselndes Lagerteils » unter « Demontage »beschriebenen Arbeiten ausführen,Seite 16
Replacement of the cam (026)
Disassembly
Do operations described in chapter "replacement of the bearing sup- port" section "disassembly" page 16
Wiedereinbau
Dazu die im Kapitel « Auswechselndes Lagerteils » unter " Wiederein-bau " beschriebenen Arbeiten ausfüh-ren, Seite 18.Allerdings muß bei Motoren mit 2Schluckvolumen mit einemSchluckvolumenverhältnis überoder unter 2 die Winkelposition be-
rücksichtigt werden.Beispiel: Motor MS18, Schluckvolu-men 1747-1049-698Kleines Schluckvolumen: 698 cm3
Buchstabe PMittleres Schluckvolumen: 1 049 cm3
Buchstabe MDie Buchstaben P oder M müssensich in der Achse befinden und inRichtung des Schiebers für dasWechseln des Schluckvolumenszeigen, auf der der Nockenring aufdem Lagerteil befestigt ist.
Reassembly
Do operations described in chapter "replacement of the bearing sup- port" section "reassembly" page 18.The angular position of the cam must be respected on dual dis- placement motors with a displace- ment ratio different from 2.
Example : Motor MS18 with dis- placement 1747-1049-698.Small displacement : 698 cm
3
[42.59 cu.in] letter P Medium displacement : 1049 cm
3
[64.01 cu.in] letter M.The letter P or M must be located in the axis and towards the displace- ment change spool, with the blind hole towards the fixing of the cam on the bearing support.
MS08MSE08
MS18MSE18
MS11MSE11
M P
2035
M
P
A R
P
M
A R
P
M
A
M
P
A R
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POCLAIN HYDRAULICS
28 REPAR MS2-18 D/GB 800378128J
Auswechseln des komplet-ten Zylinderblocks (010)
Demontage
Dazu die im Kapitel « Auswechselndes Lagerteils » unter « Demontage »beschriebenen Arbeiten ausführen,Seite 16
Replacement of the cylin- ders block assembly (010)
Disassembly
Do operations described in chapter "replacement of the bearing sup- port" section "disassembly" page 16
• Nach Demontage des Nocken-rings den Zylinderblock ausbauen.
• After removing the cam, re- move the cylinders block.
Wiedereinbau Reassembly
• Neuen O-Ring (027) einsetzen. • Install a new O-ring (027).
• Kompletten Zylinderblock (010)einsetzen.
• Install the cylinders block as- sembly (010).
• Dazu die im Kapitel« Auswechseln des Lagerteils » unter"Wiedereinbau" beschriebenen Ar-beiten ausführen, Seite 18
• Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18
6541
6542
6541
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 29
Auswechseln des Verteilers(047).
Replacement of the valving (047).
Demontage Disassembly
•
Dazu die im Kapitel« Auswechseln des kompletten Zy-linderblocks (010)» unter« Demontage » beschriebenen Ar-beiten ausführen, Seite 28.
!
Position des Verteilers(047) in Bezug auf Ver-teilerdeckel (041) kenn-zeichnen. (Motor mit 2Hubvolumen).
•
Do operations described in chapter "replacement of the cylin- ders bloc assembly (010)" section "disassembly" page 28.
!
Mark location to the valving (047) in relation to the valving cover (041) (Dual displace- ment motor).
• Den Verteiler (047) durch An-heben an den Ausrichtungszapfenoder am Flansch vom Verteilerdek-kel (041) abmontieren.
• Separate the valving (047) fromthe cover (041) by levering at theindexing pins or at the flange.
!Den Verteiler vor Staubschützen.
• Federn (052) ausbauen.• Dichtungen und Gegendichtun-
gen (048) vom Verteilerdeckel(041) herausziehen und beseitigen.
Wiedereinbau
!
Es dürfen keine Rost-,Schmutz- oder Wasser-spuren vorhanden sein.
!Protect the valving from dusts.
• Remove the springs (052).
• Remove and discard the seals
and back-up rings (048) from the cover (041).
Reassembly
!All traces of rust, mud,water must be removed .
• Neue Dichtungen und Gegen-dichtungen (048) ölen und einset-zen; dabei die Gegendichtungen sowenig wie möglich verformen.
• Lubricate and install new seals and back-up rings (048), ensuring the back up rings are twisted as lit- tle as possible.
• Die Federn (052) in ihr zuvormit Fett gefülltes Gehäuse einset-zen.
• Die Dichtungsauflageflächendes Verteilers (047) fetten.
• Den Verteiler(047) in den Ver-teilerdeckel (041) drücken
• Place the springs (052) in their housings, previously filled with grease.
• Lubricate the faces of the seals of the valving (047).
• Press the valving (047) into the cover (041).
2031
1135
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POCLAIN HYDRAULICS
30 REPAR MS2-18 D/GB 800378128J
!
Die Einbaurichtung desVerteilers (047) in bezugauf den Verteilerdeckel(041) beachten).
!
Den Einsatz des Vertei-lers (047) in den Vertei-lerdeckel (041) nichtforcieren.
!
Respect the assembly sense of the valving (047) in relation to the cover (041).
!Do not force when in- stalling the valving (047) into the cover (041).
Montage der Verteileraus-führung 1C (konstanterHubvolumen).
Valving assembly type sin- gle displacement motor.
• Keine besondere Montagerich-tung.
• No particular assembly sense.
Montage der Verteilerausfüh-rung 2C (umschaltbarerHubvolumen).
• Den gewählten Buchstaben, derdie Drehrichtung anzeigt, gegen-über dem Steuerkolben (053) an-ordnen.
POSITIONIERUNG DES VERTEI-LERS
G/ L Links
Valving assembly type Dual displacement motor .
• Write the chosen letter indicate the rotation sense in front of the displacement change spool (053).
VALVING POSITIONING
G/L Left
2031041 047
053
6758
053
047
041
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 31
D/R Rechts D/R Right
• Falls kein Buchstabe vorhandenist, die Ausrichtung anhand der beimAusbau festgelegten Markierungenvornehmen.
• Dazu die im Kapitel« Auswechseln des kompletten Zy-linderblocks (010)» unter« Wiedereinbau » beschriebenen Ar-beiten ausführen, Seite 28.
Motoren SE02 und S05
• If there is no letter, do the in- dexing according to the marks made during disassembly.
• Do operations described in chapter "replacement of the cylin- ders block" section "reassembly" page 28 .
Situation of SE02 and S05 mo- tors
SE02 Motor :SE02 motor :
S05 Motor :S05 motor
053
6757
041
047
6959
6948
G/L LinksG/L Left
D/R RechtsD/R Right
G/L LinksG/L Left
D/R RechtsD/R Right
053
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POCLAIN HYDRAULICS
32 REPAR MS2-18 D/GB 800378128J
Auswechseln der Deckel-dichtung (045)
Demontage
Replacement of the O-ring (045) of the end cover
Disassembly
• Motor auf Lagerteil stellen(Muttern sind zum Schutz der Ge-windebolzen aufgesetzt)
•
• Place the motor on the bearing support (fitted with nuts for studs protection)
• Schrauben (066) herausneh-men.
• Remove the screws (066)
• Verschlussplatte abnehmen. • Remove the end cover
• O-Ring (045) entfernen. • Discard the O-ring (045)
• Wenn Motor mit 2 Hubvolu-
men, O-Ring (057) entfernen
• Discard the O-ring (057) if the
motor has 2-displacement
6543
6544
6545
066
045057
6546
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 33
Wiedereinbau Reassembly
• Neuen O-Ring (045) einsetzen. Install a new O-ring (045).
• Wenn Motor mit 2 Hubvolu-men, neuen O-Ring (057) einset-zen, andernfalls zum nächstenSchritt übergehen
• Install a new O-ring (057) if the motor has 2-displacement. If not go to the next section
• Verschlussplatte montieren. • Install the end cover
• Schrauben (066) einsetzen undmit entsprechendem Drehmomentanziehen (siehe Schaubild Seite 38)
• Install and tighten the screws (066) to the right torque (see table page 38)
6547
6548
6544
6543
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POCLAIN HYDRAULICS
34 REPAR MS2-18 D/GB 800378128J
Auswechseln des Dreh-zahlsensors (Option)
Replacing the sensor (op- tional)
Demontage Disassembly
• Stecker (161.3) abziehen • Disconnect the connector (161.3)
• Schraube (165) aufschraubenund ausbauen
• Unscrew and remove the screw (165)
• Sensor (161) mit dem Träger(166) abziehen
• Extract the sensor (161) with its support (166)
161
166
6550
6551
6552
165
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 35
Wiedereinbau Reassembly
!
Der Dichtung (164) aufSauberkeit der Auflage-fläche dem Verteiler-deckel (041) prüfen. !
Make sure that the seal mounting surface (164) on the valving cover (041) is clean.
• Neuen Haltering (163) undneue Dichtung (164) auf den Sen-sor (161) mit seiner Distanzscheibe(167) schieben.
• Install the new brake washer (163) and the new seal (164) on the sensor (161) fitted with its adjusting sticker (167).
• Den Sensor in die Halterung(166) stecken, so daß die Dichtung(164) korrekt in ihrer Aufnahmesitzt.
• Push the sensor assembly into the support (166) until the seal (164) is in its housing.
• Sensor (041) in die Bohrungdes Verteilerdeckels bis zum Kon-takt mit dem Zylinderblock (011)schieben.
• Push the sensor into the valving cover (041) until it comes in contact with the cylinders block (011),
Die Kerbe im Steckeranschluss desSensors muss radial zur Mitte desMotors (Richtung Welle) zeigen.
the notch of the sensor should be oriented towards the center of the motor.
• Schrauben (165) einsetzen undmit entsprechendem Drehmomentanziehen (siehe Schaubild Seite38)
• Install and tighten the screw (165) to the right torque (see table page 38)
• Stecker (161.3) wieder an-schließen.
• Reconnect the connector (161.3).
6552
6551
6550
6558
2064
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POCLAIN HYDRAULICS
36 REPAR MS2-18 D/GB 800378128J
Werkzeug-Liste Tooling inventory
Standard Werkzeug Standard tools
• Innensechskant-SchlüsselHollow head
wrench 5 6 8 10 12 14
• Ring-/Maulschlüssel fürSechskantschraube
Hex head wrench 13 17 19 22 24
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 bis 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 bis 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 bis 800 N.m [120 à 600 lbf.ft]
• KorrosionsschutzfettAuto-top 2000origine AGIP
Anti-oxidizing grease
Leuchtend grüne Farbe / fluores- cent green color
• Zange für Innenringe FACOM 499.32Internal snap ring
pliers
• Abzieher FACOM U 20 B Extractor
• Sechskantschlüssel fürInnensechskantschraube
Hex head wrench 13 17 19 22 24
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
6553
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 37
Spezialwerkzeuge Special tools
• Montagewerkzeugzum Anheben derSchutzkappe oder zumKomprimieren der Tel-lerfeder.
• Mandrel for reassembling the brake cover or to compress the spring washer.
Ø A Ø B Ø C Ø D E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
F03110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F04
F05
F07
M12
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
50 [1.96] 10 [0.39] 20 [0.78]
F08
F09125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F11
F12 50 [1.96] 20 [0.78]
F18
F19
F21
M16
190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46]
70 [2.75]
10 [0.39]
30 [1.18]
• Rohr zum Festsetzendes Motors
Tube to immobi- lize the motor
• Werkzeuge zur me-chanischen Bremslö-sung.
Tools for me- chanical brake release
0759
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POCLAIN HYDRAULICS
38 REPAR MS2-18 D/GB 800378128J
AnziehdrehmomenteNm ± 10%
(Gemäß Norm DIN 912)
Tightening torques in [lbf.ft] ± 10%
(According to the standard DIN 912)
Größe Size 8.8 10.9 12.9 8.8 10.9 12.9
M6 10 14 17 7.5 10 12.5
M8 25 35 41 18.4 26 30
M10 49 69 83 36 51 61
M12 86 120 145 63.4 88.4 107
M14 135 190 230 100 140 170
M16 210 295 355 155 218 262
M18 290 405 485 214 299 358
M20 410 580 690 302 428 509
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 39
ErsatzteileNummer Bezeichnung
010 Kompletter Zylinderblock012 Kompletter Kolben Cl. 0
013 Kompletter Kolben Cl. 1015 Reparatursatz
026 Kompletter Nockenring027 O-Ring
040 Komplettes Verteilerdeckel041 Verteilerdeckel042 Schraube043 Dichtungsring044 Schraube045 O-Ring047 Verteiler
048 Dichtungssatz050 Stopfen051 O-Ring052 Feder053 Umschaltkolben054 Scheibe055 Sicherungsring056 Feder057 O-Ring059 Stif t
065 Kompletter Verschlussplatte066 Schraube067 Dichtring
070 Komplettes Lagerteil071 Lagerteil072 Innerer Lippendichtring073 Rollenlager074 Rollenlager075 Scheibensatz076 Stützring077 Sicherungsring078 Äußerer Dichtring079 Abweiser
081 Dichtungsträger087 Passfeder090 Welle091 Radbolzensatz096 Bremstrommel097 Schraube098 Bremsseil099 Sicherungsring154 Komplette Bremsbacke155 Kompletter Radzylinder156 Gegenhalter
Spare parts list Item Description
010 Cylinders-block assembly 012 Piston Cl 0 assembly
013 Piston Cl 1 assembly 015 Repair kit
026 Cam assembly 027 O-ring
040 Valving cover assembly 041 Valving cover part 042 Screw 043 Seal washer
044 Screw 045 O-ring 047 Valving
048 Seal kit 050 Plug 051 O-ring 052 Spring
053 Valve spool 054 Washer 055 Snap ring 056 Spring 057 O-ring 059 Pin
065 End cover assembly 066 Screw 067 Sealing ring
070 Bearing support assembly 071 Bearing support part 072 Radial lip seal
073 Roller bearing 074 Roller bearing 075 Set of shims 076 Thrust ring 077 Snap ring 078 Lip seal 079 Deflector
081 Seal support 087 Key 090 Shaft 091 Set of studs 096 Drum brake 097 Screw
098 Brake cable 099 Snap ring 154 Brake shoe sub-assembly 155 Brake cylinder sub-assembly 156 Brake adjustment
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POCLAIN HYDRAULICS
40 REPAR MS2-18 D/GB 800378128J
Nummer Bezeichnung 100 Komplette Bremse
101 Bremsgehäuse102 Schraube106 O-Ring107 Kolben
108 Tellerfeder109 Sicherungsring110 Welle111 Dichtsatz Bremswelle112 Schraube113 Dichtungsring135 Satz Bremslamellen141 Schutzkappe142 Stopfen143 O-Ring
150 Drehzahlsensor-Vorbereitung152 Scheibe
153 Scheibe
160 Kompletter Sensor161 Sensor162 Mutter163 Scheibe164 Dichtung
Als Satz lieferbare Baugruppe
Item Description 100 Brake assembly
101 Brake body 102 Screw 106 O-ring 107 Brake piston 108 Spring washer 109 Snap ring 110 Brake shaft
111 Seal 112 Screw 113 Seal washer 135 Brake kit 141 Cover 142 Plug 143 O-ring
150 Speed sensor predisposition 152 Washer
153 Washer
160 Speed sensor assembly 161 Speed sensor part
162 Nut 163 Washer 164 Seal
Sub-assembly sold assembled
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 41
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POCLAIN HYDRAULICS
42 REPAR MS2-18 D/GB 800378128J
Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.
Single displacement motors MS, MSE 02-05-08-11-18.
0987
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 43
0988
DichtungssatzSeal kit
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300 008 912 53
POCLAIN HYDRAULICS
44 REPAR MS2-18 D/GB 800378128J
Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.
Dual displacement motors MS, MSE 02-05-08-11-18.
0990
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POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 45
0989
DichtungssatzSeal kit
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302 008 912 53
POCLAIN HYDRAULICS
46 REPAR MS2-18 D/GB 800378128J
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303008 912 53
POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 47
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China
POCLAIN HYDRAULICS BEIJING rep. officeUnit A0808, Hui Bin OfficiesNo.8 Beichendong St.BEIJING 100101CHINATel.: 86 10 6499 3988Fax: 86 10 6499 3979e-mail: [email protected]
España & Portugal
POCLAIN HYDRAULICS SPAIN S.L.
Gran Via Carlos III n
o
84 – 1
o
3
a
08028 BARCELONAESPAÑATel.: 349 3 409 54 54Fax: 349 3 490 21 79e-mail: [email protected]
POCLAIN HYDRAULICS SROKšírova 18661900 BRNO
Tel.: 420 5 43217830Fax: 420 5 43217818e-mail: [email protected]
France
POCLAIN HYDRAULICS France SASB.P. 10660411 VERBERIE CEDEXFRANCETel.: 33 3 44 40 77 77Fax: 33 3 44 40 77 91e-mail: [email protected]
Deutschland
POCLAIN HYDRAULICS GMBHBergstrasse 10664319 PFUNGSTADTDEUTSCHLANDTel.: 49 6157 9474 0Fax: 49 6157 9474 74e-mail: [email protected]
Japan
POCLAIN HYDRAULICS KK5-4-6 KugenumashinmeFUJISAWA 251JAPANTel: 81 466 50 4400Fax: 81 466 50 4422e-mail: [email protected]
Italia
POCLAIN HYDRAULICS SRLVia Svizzera 4/A41012 CARPI (MODENA)ITALIA
Tel.: 390 59 64 22 44Fax: 390 59 64 20 44e-mail: [email protected]
United Kingdom
POCLAIN HYDRAULICS LTDNene Valley Business ParkOundlePETERBOROUGH, Cambs PE8 4HNENGLANDTel.: 44 1832 273773Fax: 44 1832 274990e-mail: [email protected]
Nederland
POCLAIN HYDRAULICS BENELUX BVPenningweg 32C4879 AM ETTEN-LEURNEDERLAND
Tel.: 31 76 5021152Fax: 31 76 5012279e-mail: [email protected]
USA
POCLAIN HYDRAULICS INC.7900 Durand AvenueP.O. BOX 801STURTEVANT, WI 53177USATel.: 1 262 554 6739Fax: 1 262 554 4860e-mail: [email protected]
POCLAIN HYDRAULICS INDUSTRIE B.P. 106
60411 VERBERIE CEDEX - France Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 e-mail: [email protected]
www.poclain-hydraulics.com
S.A.S. au capital de 85 124 000 Francs Siège social: Route de Saint Sauveur VERBERIE (OISE) R.C.S. Senlis B 414 781 823 Siret 414 781 823 00011
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7.4 Vibration motor A2FM 32
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Instructions for repair
A2FM32058 010 53
Vibration motor
008 196 03 01/1993
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008 196 03 BOMAG 1
6.01 Repair survey vibration motor
6.02 Special tools
6.03 General notes for repairs
6.04 Sealing the vibration motor
6.05 Repairing the vibration motor drive
6.00Table of Contents
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Fig. 1
1 Housing2 Connecting plate
3 Valve plate
4 Drive
5 Locking ring
6 Drive shaft
6.01 Repair survey vibration motor
Installation weight:approx. 11 kg
Opening the motor will result in the lossof all warranty and policy adjustmentclaims!
The description of the repair procedures is in accordance with economical and technical aspects. We do not recommend any further
repairs.
6.01 Repair survey vibration motor
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6.02 Special tools
1. Puller 079 944 02
Fig. 1
6.02Special tools
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6.03 General notes for repairs
Please observe the following notes whencarrying out repairs on hydraulic compo-nents!
1. Close all openings on hydraulic components.
2. Replace all seals and gaskets.
3. Check all sealing and sliding surfaces for signsof wear.
4. Fill the hydraulic components with hydraulic oilbefore taking them into operation.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
6.03 General notes for repairs
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6.04 Sealing the vibration motor
1. Mark the position of the connecting plate to thehousing and unscrew the socket head capscrews (Fig. 1).
2. Swivel the connecting plate 1 (Fig. 2) aroundthe timing pin and lift it off.
3. Cover the drive shaft with adhesive tape toprevent the new radial seal from being damag-ed (Fig. 3).
4. Remove the circlip (Fig. 4).
Fig. 1
Fig. 2
Fig. 3
Fig. 4
6.04Sealing the vibration motor
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5. Force the locking ring out (Fig. 5).
6. Remove the radial seal 1 (Fig. 6) and theO-ring (2).
7. Check the drive shaft for running grooves(Fig. 7).
8. If the running groove is very deep place anappropriate shim 1 (Fig. 8) in front of the radialseal.
Fig. 5
Fig. 6
Fig. 7
Fig. 8
6.04 Sealing the vibration motor
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9. Press the new radial seal in dry by using asuitable sleeve (Fig. 9).
10. Insert the new O-ring 1 (Fig. 10) with somegrease and fill the new radial seal (2) withgrease.
11. Knock the locking ring in by tapping it lightlywith a hammer (Fig. 11).
12. Install the circlip (Fig. 12).
Fig. 9
Fig. 10
Fig. 11
Fig. 12
6.04Sealing the vibration motor
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13. Make sure that the circlip is sitting correctly inthe groove (Fig. 13).
14. Insert new O-ring 1 (Fig. 14) with some grease.
15. Make sure that the timing pin 1 (Fig. 15) is inassembling position and attach the connectingplate.
16. Observe the marks and fasten the socket headcap screws crosswise with 25 Nm (Fig. 16).
Fig. 13
Fig. 14
Fig. 15
Fig. 16
6.04 Sealing the vibration motor
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17. Unscrew the plug 1 (Fig. 17) and insert a newO-ring (2) with some grease.
Fig. 17
6.04Sealing the vibration motor
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6.05 Repairing the vibration motor drive
Dismantling the drive
1. Mark the position of the connecting plate to thehousing and unscrew the socket head capscrews (Fig. 1).
2. Swivel the connecting plate 1 (Fig.2) aroundthe timing pin and lift it off.
3. Remove the O-ring 1 (Fig.3)
4. Remove the valve plate (2).
5. Remove the circlip (Fig. 4).
Fig. 1
Fig. 2
Fig. 3
Fig. 4
6.05 Repairing the vibration motor drive
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008 196 03 BOMAG 11
6. Force the locking ring out (Fig. 5).
7. Remove the radial seal 1 (Fig. 6) and theO-ring (2).
8. Remove the shims 1 (Fig. 7).
9. Dismantle the drive by using the puller asshown in Fig. 8.
Guide the cylinder in by hand.
Fig. 5
Fig. 6
Fig. 7
Fig. 8
6.05Repairing the vibration motor drive
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10. Check the housing for signs of scoring (Fig. 9).
Assembling the drive
The drive 1 (Fig. 10) can only be renewed completely as the hydraulical and the mechani- cal parts are adjusted to each other.
1. Insert the spring cup 1 (Fig. 11) and the Belle-ville springs (2) into the cylinder (3) by using apiece of wire.
2. Slide all pistons into the cylinder by movingthem slightly from side to side (Fig. 12).
Fig. 9
Fig. 10
Fig. 11
Fig. 12
6.05 Repairing the vibration motor drive
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008 196 03 BOMAG 13
3. Stand the new drive into a suitable bore andswash it to maximum displacement (Fig. 13).
4. Heat the housing up to a temperatur of approx.80 ˚C (Fig. 14).
5. Slide the warm housing onto the drive as far asit will go (Fig. 15).
Danger of injury!
Let the housing cool down, before furtherassembly to avoid damages to the O-ring.
6. Insert the shims 1 (Fig. 16).
Fig. 13
Fig. 14
Fig. 15
Fig. 16
6.05Repairing the vibration motor drive
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7. Press the new radial seal in dry by using asuitable sleeve (Fig. 17).
8. Insert the new O-ring 1 (Fig. 18) with somegrease and fill the new radial seal (2) withgrease.
9. Cover the drive shaft with adhesive tape toprevent the new radial seal from being damag-ed.
10. Knock the locking ring in by tapping it lightlywith a hammer (Fig. 19).
11. Install the circlip (Fig. 20).
Fig. 17
Fig. 18
Fig. 19
Fig. 20
6.05 Repairing the vibration motor drive
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12. Make sure that the circlip is sitting correctly inthe groove (Fig. 21).
13. Pull the drive against the locking ring by usingthe puller (Fig. 22).
When the drive is touching, the locking ring is free of clearance.
14. Insert the O-ring (Fig. 23) with some greaseinto the the groove.
15. Stick the valve plate (2) onto the drive by usingoil.
16. Make sure that the timing pin 1 (Fig. 24) is inassembling position and put on the connectingplate.
Fig. 21
Fig. 22
Fig. 23
Fig. 24
6.05Repairing the vibration motor drive
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17. Observe the marks and tighten the sockethead cap screws crosswise with 25 Nm (Fig.25).
18. Screw the socket head cap screw into the driveshaft and check if the drive shaft can be turnedby using an Allen key (Fig. 26).
The vibration motor has to be bled andfilled with hydraulic oil before taking it intoservice.
Fig. 25
Fig. 26
6.05 Repairing the vibration motor drive
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